Dual orientation connector with external contacts and conductive frame

ABSTRACT

A dual orientation connector having a connector tab with first and second major opposing sides and a plurality of electrical contacts carried by the connector tab. The plurality of contacts includes a first set of external contacts formed at the first major side and a second set of external contacts formed at the second major side. Each individual contact in the first plurality of contacts is electrically connected within the tab or body to a corresponding contact in the second plurality of contacts. In some embodiments contacts in the first and second pluralities of contacts that are directly opposite each other are coupled together. In some other embodiments, contacts in the first and second pluralities of contacts that are in a cater cornered relationship with each other are coupled together. The first plurality of contacts are symmetrically spaced with the second plurality of contacts and the connector tab is shaped to have 180 degree symmetry so that it can be inserted and operatively coupled to a corresponding receptacle connector in either of two insertion orientations.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/607,366, filed Sep. 7, 2012; which claims the benefit of U.S.Provisional Patent Application No. 61/556,692, filed Nov. 7, 2011, U.S.Provisional Patent Application No. 61/565,372, filed Nov. 30, 2011, andU.S. Provisional Patent Application No. 61/694,423, filed Aug. 29, 2012,which are commonly assigned, the disclosures of which are herebyincorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to electronic connectors such asaudio and data connectors.

Standard audio connectors or plugs are available in three sizesaccording to the outside diameter of the plug: a 6.35 mm (¼″) plug, a3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. Theplugs include multiple conductive regions that extend along the lengthof the connectors in distinct portions of the plug such as the tip,sleeve and one or more middle portions between the tip and sleeveresulting in the connectors often being referred to as TRS (tip, ringand sleeve) connectors.

FIGS. 1A and 1B illustrate examples of audio plugs 10 and 20 havingthree and four conductive portions, respectfully. As shown in FIG. 1A,plug 10 includes a conductive tip 12, a conductive sleeve 16 and aconductive ring 14 electrically isolated from the tip 12 and the sleeve16 by insulating rings 17 and 18. The three conductive portions 12, 14,16 are for left and right audio channels and a ground connection. Plug20, shown in FIG. 1B, includes four conductive portions: a conductivetip 22, a conductive sleeve 26 and two conductive rings 24, 25 and isthus sometime referred to as a TRRS (tip, ring, ring, sleeve) connector.The four conductive portions are electrically isolated by insulatingrings 27, 28 and 29 and are typically used for left and right audio,microphone and ground signals. As evident from FIGS. 1A and 1B, each ofaudio plugs 10 and 20 are orientation agnostic. That is, the conductiveportions completely encircle the connector forming 360 degree contactssuch that there is no distinct top, bottom or side to the plug portionof the connectors.

When plugs 10 and 20 are 3.5 mm miniature connectors, the outer diameterof conductive sleeve 16, 26 and conductive rings 14, 24, 25 is 3.5 mmand the insertion length of the connector is 14 mm. For 2.5 mmsubminiature connectors, the outer diameter of the conductive sleeve is2.5 mm and the insertion length of the connector is 11 mm long. Such TRSand TRRS connectors are used in many commercially available MP3 playersand smart phones as well as other electronic devices. Electronic devicessuch as MP3 players and smart phones are continuously being designed tobe thinner and smaller and/or to include video displays with screensthat are pushed out as close to the outer edge of the devices aspossible. The diameter and length of current 3.5 mm and even 2.5 mmaudio connectors are limiting factors in making such devices smaller andthinner and in allowing the displays to be larger for a given formfactor.

Many standard data connectors are also only available in sizes that arelimiting factors in making portable electronic devices smaller.Additionally, and in contrast to the TRS connectors discussed above,many standard data connectors require that they be mated with acorresponding connector in a single, specific orientation. Suchconnectors can be referred to as polarized connectors. As an example ofa polarized connector, FIGS. 2A and 2B depict a micro-USB connector 30,the smallest of the currently available USB connectors. Connector 30includes a body 32 and a metallic shell 34 that extends from body 32 andcan be inserted into a corresponding receptacle connector. As shown inFIGS. 2A, 2B, shell 34 has angled corners 35 formed at one of its bottomplates. Similarly, the receptacle connector (not shown) with whichconnector 30 mates has an insertion opening with matching angledfeatures that prevents shell 34 from being inserted into the receptacleconnector the wrong way. That is, it can only be inserted one way—in anorientation where the angled portions of shell 34 align with thematching angled portions in the receptacle connector. It is sometimesdifficult for the user to determine when a polarized connector, such asconnector 30 is oriented in the correct insertion position.

Connector 30 also includes an interior cavity 38 within shell 34 alongwith contacts 36 formed within the cavity. Cavity 38 is prone tocollecting and trapping debris within the cavity which may sometimesinterfere with the signal connections to contacts 36. Also, and inaddition to the orientation issue, even when connector 30 is properlyaligned, the insertion and extraction of the connector is not precise,and may have an inconsistent feel. Further, even when the connector isfully inserted, it may have an undesirable degree of wobble that mayresult in either a faulty connection or breakage.

Many other commonly used data connectors, including standard USBconnectors, mini USB connectors, FireWire connectors, as well as many ofthe proprietary connectors used with common portable media electronics,suffer from some or all of these deficiencies or from similardeficiencies.

BRIEF SUMMARY OF THE INVENTION

Various embodiments of the invention pertain to electronic connectorsthat improve upon some or all of the above described deficiencies. Otherembodiments of the invention pertain to methods of manufacturing suchelectronic connectors as well as electronic devices that include suchconnectors.

In view of the shortcomings in currently available electronic connectorsas described above, some embodiments of the present invention relate toimproved plug connectors that have a reduced plug length and thickness,an intuitive insertion orientation and a smooth, consistent feel wheninserted and extracted from its corresponding receptacle connector.Additionally, some embodiments of plug connectors according to thepresent invention only include external contacts and do not includecontacts positioned within an internal cavity that is prone tocollecting and trapping debris.

One particular embodiment of the invention pertains to an unpolarizedmultiple orientation plug connector having external contacts carried bya connector tab. The connector tab can be inserted into a correspondingreceptacle connector in at least two different insertion orientations.Contacts are formed on first and second surfaces of the tab and arrangedin a symmetrical layout so that the contacts align with contacts of thereceptacle connector in either of at least two insertion orientations.One or more individual contacts in the first plurality of contacts areelectrically coupled within the tab or body of the connector to acorresponding contact in the second plurality of contacts. Additionally,the connector tab itself can have a symmetrical cross-sectional shape tofacilitate the multi-orientation aspect of this embodiment.

Another embodiment pertains to a dual orientation plug connector thatincludes a body and a 180 degree symmetrical metal tab connected to andextending longitudinally away from the body. The tab includes first andsecond major opposing surfaces and third and fourth minor opposingsurfaces that extend between the first and second major surfaces. Afirst contact region formed at the first major surface of the tabincludes a first plurality of external contacts spaced apart along afirst row. A second contact region formed at the second major surface ofthe tab includes a second plurality of external contacts spaced apartalong a second row that mirrors the first row. Each individual contactin the first plurality of contacts is electrically connected within thetab or body to a corresponding contact in the second plurality ofcontacts, and dielectric material is filled in between adjacent contactsin the first and second rows and between the contacts and the metal tab.In some embodiments first and second retention features adapted toengage with retention features on a corresponding receptacle connectorare formed on the third and fourth minor surfaces of the tab.

Still another embodiment of the invention pertains to a plug connectorthat includes a body and a tab connected to and extending away from thebody. The tab includes first and second major opposing surfaces alongwith third and fourth minor opposing surfaces that extend between thefirst and second major surfaces. A first contact region that includeseight sequentially numbered external contacts spaced apart along a firstrow is formed at the first major surface of the tab. The sequentiallynumbered contacts include first and second contacts designated for datasignals at locations 2 and 3, first and second power contactselectrically coupled to each other and designated for power at locations4 and 5, and third and fourth contacts designated for data signals atlocations 6 and 7. In some embodiments the plug connector furtherincludes an accessory power contact at one of locations 1 or 8 and an IDcontact at the other of locations 1 or 8. In some embodiments the plugconnector also has a second contact region formed at the second majorsurface of the tab that includes eight sequentially numbered externalcontacts spaced apart along a second row. The second row is directlyopposite from and mirrors the first row, and each individual contact inthe second first row is electrically connected to a correspondingcontact in the second row.

Still another embodiment of the invention pertains to a reversible plugconnector that includes a body and connector tab coupled to andextending away from the body. The tab including first and secondopposing surfaces along with third and fourth opposing surfaces thatextend between the first and second surfaces. A first contact region isformed at the first surface of the tab that includes eight externalcontacts spaced apart along a first row. A second contact region isformed at the second surface of the tab that includes eight externalcontacts spaced apart along a second row in contact locations thatmirror contact locations in the first row. In one version of thisembodiment, each of the first and second rows includes a single groundcontact designated for ground, a first pair of data contacts that can beused to carry data signals according to a first communication protocol,and a second pair of data contacts that can be used to carry datasignals according to a second communication protocol different than thefirst protocol. Additional versions of this embodiment may furtherinclude one or more of a power in contact designated to carry a firstpower signal at a first voltage, a power out contact capable of carryinga second power signal at a second voltage lower than the first voltage,and an ID contact capable of carrying a configuration signal thatidentifies the communication protocols used by the first and secondpairs of data contacts. In various additional versions of thisembodiment, the contacts are arranged according to one or more of thefollowing rules: (i) the first pair of data contacts in the first andsecond rows are positioned in a mirrored relationship directly oppositeeach other, (ii) the second pair of data contacts in the first row andsecond rows are positioned in a mirrored relationship directly oppositeeach other, (iii) the ground contacts in the first and second rows arepositioned in a cater corner relationship with each other across acenterline of the connector; (iv) the first power contact in the firstand second rows are positioned in a cater corner relationship with eachother across a centerline of the connector; (v) the ID contacts in thefirst and second rows are positioned in a cater corner relationship witheach other across a first quarter line of the connector; and (vi) thesecond power contacts in the first and second row are positioned in acater corner relationship with each other across a second quarter lineof the connector.

To better understand the nature and advantages of the present invention,reference should be made to the following description and theaccompanying figures. It is to be understood, however, that each of thefigures is provided for the purpose of illustration only and is notintended as a definition of the limits of the scope of the presentinvention. Also, as a general rule, and unless it is evident to thecontrary from the description, where elements in different figures useidentical reference numbers, the elements are generally either identicalor at least similar in function or purpose.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B show perspective views of previously known TRS and TRRSaudio plug connectors respectively;

FIG. 2A shows a perspective view of a previously known micro-USB plugconnector while FIG. 2B shows a front plan view of the micro-USBconnector shown in FIG. 2A;

FIG. 3A is simplified top view of a plug connector 40 according to oneembodiment of the present invention;

FIGS. 3B and 3C are simplified side and front views, respectively, ofconnector 40 shown in FIG. 3A;

FIGS. 4A-4E are front views of alternative embodiments of connector 40according to the present invention;

FIGS. 5A and 5B are simplified top and side view of a plug connector 50according to another embodiment of the present invention;

FIGS. 5C and 5D are simplified top and bottom perspective views of oneembodiment of a ground ring that can be included in some embodiments ofthe present invention;

FIG. 6A is simplified top view of a plug connector 60 according toanother embodiment of the present invention;

FIG. 6B is a simplified perspective views of another embodiment of aground ring according to the present invention;

FIGS. 7A-7H are simplified top views of contact layouts within contactregion 46 according to different embodiments of the invention;

FIGS. 8A and 8B are simplified views of an embodiment of a plugconnector 80 having four contacts on each major opposing surface of tab44 according to an embodiment of the present invention;

FIG. 8C is a simplified cross-sectional schematic view of plug connector80 shown in FIGS. 8A and 8B taken along line A-A′;

FIGS. 9A and 9B are diagrams depicting the alignment of contacts in plugconnector 80 with corresponding contacts in receptacle connector 85 indifferent insertion orientations according to one embodiment of theinvention;

FIGS. 10A and 10B are simplified views of another embodiment of a plugconnector 90 having four contacts on each opposing surface of tab 44according to an embodiment of the present invention;

FIG. 10C is a simplified cross-sectional schematic view of plugconnector 90 shown in FIG. 10A taken along line B-B′;

FIGS. 11A and 11B are diagrams depicting the alignment of contacts inplug connector 90 with corresponding contacts in receptacle connector 85in different insertion orientations according to one embodiment of theinvention;

FIG. 12A is a simplified view of another embodiment of a plug connector99 having three contacts on each opposing surface of tab 44 according toand embodiment of the present invention;

FIGS. 12B and 12C are diagrams depicting the alignment of contacts inplug connector 99 with corresponding contacts in receptacle connector 95in different insertion orientations according to one embodiment of theinvention;

FIG. 13A is a simplified perspective view of a plug connector 100 havingeight contacts formed on each opposing surface of tab 44 according toone embodiment of the present invention;

FIGS. 13B and 13C are simplified top and bottom views of plug connector100 shown in FIG. 13A;

FIG. 14A is a diagram illustrating a pinout arrangement of connector 100according to one embodiment of the invention;

FIG. 14B is a diagram illustrating a pinout arrangement of connector 100according to another embodiment of the invention;

FIG. 15A is a schematic representation of a receptacle connector 140according to an embodiment of the invention;

FIG. 15B is a front plan view of receptacle connector 140 according toone embodiment of the invention;

FIGS. 15C and 15D are diagrams illustrating a pinout arrangement ofconnector 140 according to two different embodiments of the inventionconfigured to mate with plug connectors having a pinout 106 a and 106 b,respectively, as shown in FIGS. 14A and 14B;

FIGS. 16A-16K are simplified views depicting a sequence of eventsassociated with mating plug connector 100 to receptacle connector 140according to one embodiment of the invention;

FIG. 17 is a schematic representation of receptacle connector 140coupled to switching circuitry 150 within a host device according to anembodiment of the invention;

FIG. 18 is a simplified perspective view of a USB charger/adapter cable160 having a USB connector at one end and a connector according to anembodiment of the invention at the other end;

FIG. 19A is a diagram depicting pin locations of plug connector 162shown in FIG. 18 according to one embodiment of the invention whereconnector 162 is compatible with the pinout shown in FIG. 14A;

FIG. 19B is a diagram depicting pin locations of plug connector 162shown in FIG. 18 according to another embodiment of the invention whereconnector 162 is compatible with the pinout shown in FIG. 14B;

FIG. 20 is a simplified schematic representation of USB charger/adapter160 according to an embodiment of the invention;

FIG. 21 is a simplified perspective view of a docking station 170according to an embodiment of the invention;

FIG. 22 is a simplified top plan view of a video adapter 180 accordingto an embodiment of the invention;

FIG. 23A is a diagram depicting pin locations of plug connector 182shown in FIG. 22 according to one embodiment of the invention whereconnector 182 is compatible with the pinout shown in FIG. 14A;

FIG. 23B is a diagram depicting pin locations of plug connector 182shown in FIG. 22 according to one embodiment of the invention whereconnector 182 is compatible with the pinout shown in FIG. 14B;

FIG. 24 is a simplified schematic representation of video adapter 180according to an embodiment of the invention;

FIG. 25 is a simplified top plan view of an SD card adapter 190according to an embodiment of the invention;

FIG. 26A is a diagram depicting pin locations of plug connector 192shown in FIG. 25 according to one embodiment of the invention whereconnector 192 is compatible with the pinout shown in FIG. 14A;

FIG. 26B is a diagram depicting pin locations of plug connector 192shown in FIG. 25 according to another embodiment of the invention whereconnector 192 is compatible with the pinout shown in FIG. 14B;

FIG. 27 is a simplified schematic representation of video adapter 190according to an embodiment of the invention;

FIG. 28A is a simplified schematic representation of an accessoryadapter 200 according to an embodiment of the invention;

FIG. 28B is a diagram depicting the pinout of connector 205 includedwithin adapter 200 according to one embodiment of the invention;

FIG. 29 is a flowchart depicting steps associated with manufacturingconnector 100 shown in FIGS. 13A-13C according to one embodiment of theinvention;

FIGS. 30A-30T depict various views of connector 100 at different stagesof manufacture discussed with respect to FIG. 29;

FIG. 31 is a flowchart depicting various sub-steps associated withattaching contact assemblies to a printed circuit board as done in step130 shown in FIG. 29 according to one embodiment of the invention;

FIG. 32 is a simplified illustrative block diagram of an electronicmedia device suitable in which embodiments of the invention may beincorporated or used with; and

FIG. 33 depicts an illustrative rendering of one particular embodimentof an electronic media device suitable for use with embodiments of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described in detail with reference tocertain embodiments thereof as illustrated in the accompanying drawings.In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present invention. Itwill be apparent, however, to one skilled in the art, that the presentinvention may be practiced without some or all of these specificdetails. In other instances, well known details have not been describedin detail in order not to unnecessarily obscure the present invention.

In order to better appreciate and understand the present invention,reference is first made to FIGS. 3A-3C, which are simplified top, sideand front views, respectively, of a dual orientation plug connector 40according to one embodiment of the present invention. Connector 40includes a body 42 and a tab portion 44 that extends longitudinally awayfrom body 42 in a direction parallel to the length of the connector 40.As shown in FIGS. 3A and 3B, a cable 43 can optionally be attached tobody 42 at an end opposite of tab portion 44. Tab 44 is sized to beinserted into a corresponding receptacle connector during a mating eventand includes a first contact region 46 a formed on a first major surface44 a and a second contact region 46 b (not shown in FIGS. 3A-3C) formedat a second major surface 44 b opposite surface 44 a. Tab 44 alsoincludes first and second opposing side surfaces 44 c, 44 d that extendbetween the first and second major surfaces 44 a, 44 b.

Contact regions 46 a and 46 b are centered between the opposing sidesurfaces 44 c and 44 d, and a plurality of external contacts (not shownin FIGS. 3A-3C) can be formed at an outer surface of tab 44 in eachcontact region. The contacts can be raised, recessed or flush with theexternal surface of tab 44 and positioned within the contact regionssuch that when tab 44 is inserted into a corresponding receptacleconnector they can be electrically coupled to corresponding contacts inthe receptacle connector. In some embodiments, the plurality of contactsare self-cleaning wiping contacts that, after initially coming intocontact with a receptacle connector contact during a mating event, slidefurther past the receptacle connector contact with a wiping motionbefore reaching a final, desired contact position. The contacts withinregions 46 a and 46 b can be made from copper, nickel, brass, stainlesssteel, a metal alloy or any other appropriate conductive material orcombination of conductive materials. In some embodiments contacts can beprinted on surfaces 44 a and 44 b using techniques similar to those usedto print contacts on printed circuit boards. In some other embodimentsthe contacts can be stamped from a lead frame, positioned within regions46 a and 46 b and surrounded by dielectric material.

In some embodiments, one or more ground contacts can be formed on of tab44. For example, FIGS. 3A and 3B show a ground contact 47 a formed onfirst side surface 44 c and a ground contact 47 b formed on second sidesurface 44 d opposite ground contact 47 a. As another example, one ormore ground contacts may be formed on end surface 44 e at the distal tipof connector 40 in addition to, or instead of ground contacts 47 a, 47b. In some embodiments, each of the one or more ground contacts can beformed on or form part of an outer portion of its respective sidesurface. In other embodiments, the one or more ground contacts can beformed within and/or as part of a pocket, indentation, notch or similarrecessed region formed on each of the side surfaces 44 c, 44 d thatoperatively engage with a retention mechanism in a correspondingreceptacle connector as described in detail below.

Tab 44 can have a 180 degree symmetrical, double orientation designwhich enables the connector to be inserted into a correspondingreceptacle connector in both a first orientation where surface 44 a isfacing up or a second orientation where surface 44 a is rotated 180degrees and facing down. To allow for the orientation agnostic featureof connector 40, connector 40 is not polarized. That is, connector 40does not include a physical key configured to mate with a matching keyin a corresponding receptacle connector and ensure that mating betweenthe two connectors occurs only in a single orientation. Additionally,contacts can be positioned within contact regions 46 a and 46 b so thatindividual contacts in region 46 a are arranged symmetric with theindividual contacts in region 46 b located on the opposite side of tab44, and ground contacts formed at the tip or on the sides of connectortab 44 can also be arranged in a symmetric manner. The symmetricalarrangement of contacts allows the contacts of the plug connector ineither region 46 a or 46 b to properly align with the contacts in thereceptacle connector regardless of orientation.

In some embodiments, tab 44 is shaped so that if the tab is divided intotop and bottom halves along a horizontal plane that bisects the centerof tab 44 (as shown by plane, P1, in FIG. 3C), the physical shape of thecross-section of upper half of tab 44 is substantially the same as thephysical shape of the cross-section of the lower half. Similarly, if tab44 is divided into left and right halves along a vertical plane thatbisects the center of tab (as shown by plane, P2, in FIG. 3C), thephysical shape of the left half of tab 44 is substantially the same asthe shape of the right half. In other dual orientation embodiments, thecross-sectional shape of tab 44 need not be fully symmetrical as long asthe connector does not include a key that prevents the connector frombeing inserted into a corresponding receptacle connector in twodifferent orientations and the contacts align properly in eitherorientation with contacts in the corresponding receptacle connector.

In addition to the 180 degree symmetrical, dual orientation design, plugconnectors according to some embodiments of the invention electricallyconnect each contact formed at surface 44 a of the connector with acorresponding contact on surface 44 b on the opposite side of theconnector. That is, in some embodiments of the invention, every contactin contact region 46 a is electrically connected to a correspondingcontact in contact region 46 b. Thus, any given signal that is to becarried by the plug connector is sent over a contact within contactregion 46 a as well as a contact within region 46 b. The effect of thisaspect of some embodiments of the invention is that the number ofdifferent signals that can be carried by a given number of contacts isreduced by half as compared to if the contacts formed in regions 46 aand 46 b were electrically isolated from each other and designated fordifferent signals. This feature provides a benefit, however, in that thecorresponding receptacle connector need only have contacts on onesurface within its cavity (for example, a top surface or a bottomsurface). The receptacle connector can thus be made thinner than areceptacle connector with contacts on both the top and bottom surfacesof its cavity, which in turn, enables an electronic device in which thereceptacle connector is housed to be thinner as well.

Body 42 is generally the portion of connector 40 that a user will holdonto when inserting or removing connector 40 from a correspondingreceptacle connector. Body 42 can be made out of a variety of materialsand in some embodiments is made from a dielectric material, such as athermoplastic polymer formed in an injection molding process. While notshown in FIG. 3A or 3B, a portion of cable 43 and a portion of tab 44may extend within and be enclosed by body 42. Electrical contact to thecontacts in contact regions 46 a, 46 b can be made to individual wiresin cable 43 within body 42. In one embodiment, cable 43 includes aplurality of individual insulated wires, one for each electricallyunique contact within regions 46 a and 46 b, that are soldered tobonding pads on a printed circuit board (PCB) housed within body 42.Each bonding pad on the PCB is electrically coupled to a correspondingindividual contact within one of contact regions 46 a or 46 b. Also, oneor more integrated circuits (ICs) can be operatively coupled within body42 to the contacts within regions 46 a, 46 b to provide informationregarding connector 40 and/or an accessory the connector is part of orto perform other specific functions as described in detail below.

In the embodiment illustrated in FIGS. 3A and 3B, body 42 has arectangular cross section that generally matches in shape but isslightly larger than the cross section of tab 42. As discussed withrespect to FIGS. 4A-4E, body 42 can be of a variety of shapes and sizes,however. For example, body 42 may have a rectangular cross section withrounded or angled edges (referred to herein as a “generally rectangular”cross section), a circular cross section, an oval cross section as wellas many other suitable shapes. In some embodiments, both the body 42 andtab 44 of connector 40 have the same cross-sectional shape and have thesame width and height (thickness). As one example, body 42 and tab 44may combine to form a substantially flat, uniform connector where thebody and tab seem as one. In still other embodiments, the cross sectionof body 42 has a different shape than the cross section of tab 44, forexample, body 42 may have curved upper and lower and/or curved sidesurfaces while tab 44 is substantially flat.

Also, the embodiment shown in FIGS. 3A-3C includes connector 40 as partof a cable connector. In some embodiments, plug connectors according tothe invention are used in devices such as docking stations, clock radiosand other accessories or electronic devices. In such embodiments, tab 44may extend directly out of a housing associated with the dockingstation, clock radio or other accessory or electronic device. Thehousing associated with the accessory or device, which may be shapedvery differently than body 42, can then be considered the body of theconnector.

While tab 44 is shown in FIGS. 3A-3C as having a substantiallyrectangular and substantially flat shape, in some embodiments of theinvention first and second major surfaces 44 a, 44 b may have matchingconvex or concave curvatures to them or may have a matching recessedregion centrally located between the sides of tab 44. Contact regions 46a and 46 b may be formed in the recessed regions and the recessedregions may, for example, extend from the distal tip of tab 44 all theway to base 42 or may extend along only a portion of the length of tab44 (e.g., between ½ to ¾ of the length of the tab) ending at a pointshort of base 42. Side surfaces 44 c and 44 d may also have matchingconvex or concave curvatures.

Generally, the shape and curvature of surfaces 44 a and 44 b mirror eachother, as do the shape and curvature of surfaces 44 a and 44 b, inaccordance with the dual orientation design of connector 40 as describedbelow. Additionally, while FIGS. 3A-3C show surfaces 44 c, 44 d ashaving a width significantly less than that of surfaces 44 a, 44 b(e.g., less than or equal to one quarter or one half the width ofsurfaces 44 a, 44 b), in some embodiments of the invention side surfaces44 c, 44 d have a width that is relatively close to or even equal withor wider than that of surfaces 44 a, 44 b.

FIGS. 4A-4E are simplified front plan views of embodiments of connector40 in which body 42 and/or tab 44 have different cross-sectional shapes.For example, in FIG. 4A, major surfaces 44 a and 44 b are slightlyconvex, while in FIGS. 4B and 4C, side surfaces 44 c and 44 d arerounded. FIG. 4C depicts an example of a connector having recessedregions 45 a and 45 b formed at major surfaces 44 a and 44 b,respectfully, of tab 44. The recessed regions extend from the distal tipof tab 44 along a portion of the length of tab 44 and are centrallylocated between side surfaces 44 c and 44 d. FIG. 4D depicts an exampleof a connector in which tab 44 has a dog-bone shaped cross-section whereridges 45 c and 45 d are formed at the sides of the tab. A correspondingreceptacle connector may include a cavity shaped to match the ridges sothat ridges 45 c, 45 d help align the connector into the cavity during amating event. FIG. 4E depicts an example of a connector in which body 42has approximately the same width as tab 44 but is larger than the tab inthe height direction. A person of skill in the art will understand thatFIGS. 3C and 4A-4E are but examples of suitable cross-sectional shapesfor body 42 and tab 44 and that many other cross-sectional shapes may beemployed for each of body 42 and tab 44 in various embodiments of theinvention.

Tab 44 may be made from a variety of materials including metal,dielectric or a combination thereof. For example, tab 44 may be aceramic base that has contacts printed directly on its outer surfaces orcan include a frame made from an elastomeric material that includes flexcircuits attached to the frame. In some embodiments, tab 44 includes anexterior frame made primarily or exclusively from a metal, such asstainless steel, and contact regions 46 a and 46 b are formed withinopenings of the frame as shown, for example, in FIGS. 5A-5C.

FIGS. 5A and 5B are simplified top and side views of a plug connector 50according to an embodiment of the invention. Plug connector 50 includesmany of the same features as plug connector 40 but further includesfirst and second retention features 54 a and 54 b that are adapted toengage with retention features on a corresponding receptacle connectorto secure the connectors together during a mating event. Additionally, aframe 52, which is sometimes referred to as a shell and can be referredto as a ground ring when made from an electrically conductive material,provides structural support for the connector and defines the exteriorshape of tab 44.

As shown in FIGS. 5C and 5D, which are simplified perspective top andbottom views, respectively, of frame 52, the frame may include first andsecond opposing sides 52 a, 52 b extending in the width and lengthdimensions of the frame, third and fourth opposing sides 52 c, 52 dextending between the first and second sides in the height and lengthdimensions, and an end 52 e extending in the width and height dimensionsbetween the first and second sides as well as between the third andfourth sides at the distal end of the frame. Sides 52 a-52 e frame acavity 55 that can house portions of connector 50. Opposing openings 56a and 56 b to cavity 55 are formed in sides 52 a and 52 b, respectively.Opening 56 a defines the location of first contact region 46 a, whileopening 56 b, which in some embodiments has the same size and shape asopening 56 a, defines the location of second contact region 46 b. Thus,as shown in FIGS. 5C and 5D, each of the contact regions is completelysurrounded in the X and Y axis by the outer surface of frame 52. Such aconfiguration is particularly useful when frame 52 is made from anelectrically conductive material, such as stainless steel or anotherhard conductive metal. In such embodiments, frame 52 can be grounded(and thus can be referred to as ground ring 52) in order to minimizeinterference that may otherwise occur on the contacts of connector 50.Thus, in some embodiments, ground ring 52 may provide electrostaticdischarge (ESD) protection and electromagnetic compatibility (EMC) andact as a single ground reference for all signals carried over theconnector.

First and second retention features 54 a and 54 b can be formed on theopposing sides of tab 44 within frame 52. Retention features 54 a, 54 bare part of a retention system that includes one or more features on theplug connector that are adapted to engage with one or more features onthe corresponding receptacle connector to secure the connectors togetherwhen the plug connector is inserted into the receptacle connector. Inthe illustrated embodiment, retention features 54 a, 54 b aresemi-circular indentations in the side surfaces of tab 44 that extendfrom surface 44 a to surface 44 b. The retention features may be widelyvaried and may include angled indentations or notches, pockets that areformed only at the side surfaces and do not extend to either of thesurfaces 44 a, 44 b upon which contact regions 46 a, 46 b are formed, orother recessed regions. The retention features are adapted to engagewith a retention mechanism on the receptacle connector that can besimilarly widely varied. The retention mechanism(s) may be, for example,one or more springs that includes a tip or surface that fits withinindentations 54 a, 54 b, one or more spring loaded detents, or similarlatching mechanisms. The retention system, including retention features54 a, 54 b and the corresponding retention mechanism on the receptacleconnector, can be designed to provide specific insertion and extractionforces such that the retention force required to insert the plugconnector into the receptacle connector is higher than the extractionforce required to remove the plug connector from the receptacleconnector.

While retention features 54 a, 54 b are shown in FIGS. 5A-5C as having afemale mating characteristic and the retention mechanism associated withthe receptacle connector was described above as having a malecharacteristic that is moved into the retention features 54 a, 54 b, inother embodiments these roles may differ. For example, in oneembodiment, retention features 54 a, 54 b may be spring loadedprojections that engage with a female retention mechanism on thereceptacle connector. In still other embodiments, one of features 54 a,54 b may be male-oriented while the other of features 54 a, 54 b isfemale-oriented. In other embodiments, other retention mechanisms can beused such as mechanical or magnetic latches or orthogonal insertionmechanisms. Additionally, while retention features 54 a and 54 b areshown in FIG. 5A as being formed in frame 52, in embodiments of theinvention that do not include a frame, the retention features can beformed in whatever structure or material makes up tab 44.

Retention features 54 a, 54 b can also be located at a variety ofpositions along connector 50 including along the side surfaces of tab 44and/or top and bottom surfaces of tab 44. In some embodiments, retentionfeatures 54 a, 54 b can be located on a front surface 42 a of body 42and adapted to engage with a retention mechanism located on a frontexterior surface of the receptacle connector. In the embodimentillustrated in FIGS. 5A-5C, retention features 54 a, 54 b are positionedwithin the last third of the length of tab 44. The inventors havedetermined that positioning the retention features and correspondinglatching mechanism in the receptacle connector near the end of the plugconnector helps to better secure the connector sideways when it is in anengaged position within the receptacle connector.

Reference is now made to FIGS. 6A and 6B. FIG. 6A is a simplified topview of a plug connector 60 according to another embodiment of theinvention, while FIG. 6B is a simplified perspective view of a frame 62that forms part of tab 44 of connector 60. Frame 62 is a u-shaped framethat extends from the distal tip of connector 60 along the side of theconnector towards body 42 and has a thickness that is equivalent to thethickness (T) of connector 60. Frame 62 includes side portions 62 a, 62b that may have varying lengths in different embodiments. In someembodiments sides 62 a, 62 b extend past contact regions 46 a, 46 b allthe way to the body 42 of the connector. In other embodiments the sidesmay extend past contact regions 46 a, 46 b but not all the way to body42 (as shown in FIG. 7B); may extend exactly to the end of contactregions 46 a, 46 b or may be relatively short and extend only partiallyalong the length of the contact regions. Contact regions 46 a, 46 b liebetween the opposing sides 62 a, 62 b. As with frame 52, frame 62 can bemade out of an electrically conductive material and referred to asground ring 62.

The contact regions 46 a, 46 b in any of connectors 40, 50 or 60discussed above (as well as connectors 80, 90, 100 and others discussedbelow) may include any number of external contacts, from one to twentyor more arranged in a variety of different patterns. FIGS. 7A-7H providedifferent examples of contact arrangements within a contact region 46according to different embodiments of the invention. As shown in FIG.7A, contact region 46 may include two contacts 71(1) and 71(2) that arecentered and symmetrically positioned within the contact region.Similarly, FIG. 7B depicts a contact region 46 having three contacts72(1) . . . 72(3) centered and symmetrically positioned within thecontact region, while FIGS. 7C and 7D depict contact regions 46 havingfour such contacts, 73(1) . . . 73(4), and eight such contacts, 74(1) .. . 74(8), respectively.

In some embodiments, individual contacts may be sized differently. Thismay be particularly useful, for example, where one or more contacts arededicated to carry high power or high current. FIG. 7E depicts one suchembodiment where seven contacts 75(1) . . . 75(7) are arranged in asingle row within contact region 46 and a center contact 75(4) is two orthree times as wide as the other contacts.

While each of FIGS. 7A-7E include a single row of contacts within region46, some embodiments of the invention may include two, three or morerows of contacts. As examples, contact region 46 shown in FIG. 7Fincludes two rows of four contacts 76(1) . . . 76(4) and 76(5) . . .76(8) with each row being centered between the sides of the contactregion and symmetrically spaced with respect to a center line traversingthe length of the contact region;

FIG. 7G shows a contact region 46 having a first row of three contacts77(1) . . . 77(3) and a second row of four contacts 77(4) . . . 77(7)positioned within the contact region; and FIG. 7H depicts a contactregion 46 having three rows of three contacts for a total of ninecontacts 78(1) . . . 78(9).

Each of the contact regions 46 shown in FIGS. 7A-7H is representative ofboth regions 46 a and 46 b according to particular embodiments of theinvention. That is, according to one embodiment of the invention, a plugconnector may include two contact regions 46 a and 46 b each of whichincludes two contacts as shown in region 46 in FIG. 7A. In anotherembodiment, a plug connector may include contact regions 46 a and 46 beach of which includes three contacts as shown in FIG. 7B. Still otherembodiments of the invention include: a plug connector having contactregions 46 a and 46 b as shown in region 46 in FIG. 7C; a plug connectorhaving contact regions 46 a and 46 b as shown in region 46 in FIG. 7D; aplug connector having contact regions 46 a and 46 b as shown in region46 in FIG. 7E; a plug connector having contact regions 46 a and 46 b asshown in region 46 in FIG. 7F; a plug connector having contact regions46 a and 46 b as shown in region 46 in FIG. 7G; and a connector 40having contact regions 46 a and 46 b as shown in region 46 in FIG. 7H.

Contacts within regions 46 a, 46 b may include contacts designated for awide variety of signals including power contacts, ground contacts,analog contacts and digital contacts among others. In some embodiments,one or more ground contacts are formed in regions 46 a and 46 b while inother embodiments, ground contacts are only located at the tip 44 eand/or on the side surfaces 44 c, 44 d of connector 40. Embodiments thatemploy ground contacts at one or more positions along the peripheralside and/or tip surfaces of connector 40 instead of within contactregions 46 a and 46 b may enable the overall footprint of connector tab44 to be smaller than a similar connector that includes ground contactsin contact regions 46 a or 46 b.

Power contacts within regions 46 a, 46 b may carry signals of anyvoltage and, as an example, may carry signals between 2-30 volts. Insome embodiments, multiple power contacts are included in regions 46 a,46 b to carry power signals of different voltages levels that can beused for different purposes. For example, one or more contacts fordelivering low current power at 3.3 volts that can be used to poweraccessory devices connected to connector 40 can be included in regions46 a, 46 b as well as one or more contacts for delivering high currentpower at 5 volts for charging portable media devices coupled toconnector 40. As discussed with respect to FIG. 7E, in some embodimentsone or more power contacts within regions 46 a, 46 b can be larger thanother contacts to more efficiently enable the larger contacts to carryhigh power and/or high current. In other embodiments, multiple contactscan be electrically coupled together to provide one or more “largercontacts” for carrying high power and/or high current. For example, inone embodiment contacts 74(4) and 75(5) shown in FIG. 7D may beelectrically coupled together to act as a single power contact.

Examples of analog contacts that may be included in contact regions 46a, 46 b include contacts for separate left and right channels for bothaudio out and audio in signals as well as contacts for video signals,such as RGB video signals, YPbPr component video signals and others.Similarly, many different types of digital signals can be carried bycontacts in regions 46 a, 46 b including data signals such as, USBsignals (including USB 1.0, 2.0 and 3.0), FireWire (also referred to asIEEE 1394) signals, UART signals, Thunderbolt signals, SATA signalsand/or any other type of high speed serial interface signal or othertype of data signal. Digital signals within contact regions 46 a, 46 bmay also include signals for digital video such as DVI signals, HDMIsignals and Display Port signals, as well as other digital signals thatperform functions that enable the detection and identification ofdevices or accessories to connector 40.

In some embodiments, dielectric material is filled in between individualcontacts in contact regions 46 a, 46 b by, for example, using injectionmolding techniques so that it is flush with the upper surface of thecontacts. The dielectric material separates adjacent contacts from eachother and separates the set of contacts in the contact region from theframe or the metal surface of the ground ring that surrounds thecontacts. In some embodiments the dielectric material and contacts forma flush outer surface of tab 44 that provides a smooth, consistent feelacross the surfaces of tab 44, while in other embodiments, each ofcontact regions 46 a, 46 b, including the dielectric material andcontacts, may be recessed a very small amount (e.g., between 0.2 and0.01 mm) to help ensure that none of the individual contacts protrudeabove the outer surface of frame 52, which increases the susceptibilitythat, over 1000's of use cycles, the protruding or “proud” contact willsomehow be mechanically dislodged from the connector. Additionally, toimprove robustness and reliability, connector 40 can be fully sealed andincludes no moving parts.

To better understand and appreciate the 180 degree symmetrical dualorientation design of some embodiments of the invention, reference ismade to FIGS. 8A-8C which depict a plug connector 80 according to aspecific embodiment of the invention that includes four individualcontacts formed within each of contact regions 46 a and 46 b.Specifically, FIGS. 8A and 8B are simplified views of a first side 44 aand an opposing second side 44 b, respectively, of connector 80, whileFIG. 8C is a simplified cross-sectional view of connector 80 taken alongline A-A′ (shown in FIG. 8A) that also includes a schematicrepresentation of electrical connections between the contacts of theconnector. As shown in FIG. 8C, each of contacts 73(1) . . . 73(4) atsurface 44 a of connector 80 is electrically coupled to a contactdirectly opposite itself at surface 44 b by an electrical connection82(1) . . . 82(4) that is represented in schematic form. For ease ofreference, contacts that are electrically coupled together on twodifferent sides of the connector are referred to by the same contactnumber and are sometimes referred to herein as a “corresponding pair” ofcontacts or “matching connected contacts”. Electrical contact betweencorresponding pairs of contacts can be made in a variety of ways. Insome embodiments electrical contact between contacts in a correspondingpair is made within tab 44 or body 42. As one example, a printed circuitboard (PCB) that includes contact pads printed on its upper and lowersurfaces can extend within tab 44. Through holes or vias may be formedin the printed circuit board directly between contact pads on opposingsurfaces and filled with an electrically conductive material (e.g.,copper) to electrically connect each contact pad formed on the uppersurface to a corresponding contact pad on the opposite surface.Individual contacts at surface 44 a of the connector soldered to contactpads on one side of the PCB can thus be electrically connected tomatching connected contacts at surface 44 b soldered to contact pads onthe other side of the PCB. In other embodiments where a ground ring doesnot surround the contacts at the tip of the connector, the contacts canbe coupled together by wrapping around the tip of the connector fromsurface 44 a to surface 44 b instead of being electrically connectedthrough tab 44.

Turning now to FIG. 8A and the dual orientation aspect of connector 80,contact region 46 a may include four evenly spaced contacts 73(1) . . .73(4) formed within the region. With respect to a center plane 59 thatis perpendicular to and passes through the middle of connector 50 alongits length, contacts 73(1) and 73(2) are in a mirrored relationship withcontacts 73(3) and 73(4) across center line 59. That is, the spacingfrom center line 59 to contact 73(2) is the same as the spacing fromcenter line 59 to contact 73(3). Also, the spacing from center line 59to contact 73(1) is the same as the spacing from centerline 59 tocontact 73(4). Contacts in each of the pairs of contacts 73(1), 73(4)and 73(2), 73(3) are also spaced equally from the sides 44 c and 44 d ofthe connector with respect to each other and are spaced along the lengthof tab 44 an equal distance from end surface 44 e.

Similarly, in FIG. 8B contact region 46 b includes the same number ofcontacts as region 46 a that are also spaced according to the samespacing as in region 46 a. Thus, contact region 46 b includes fourcontacts 73(1) . . . 73(4) spaced within region 46 b according to thesame layout and spacing as contacts 73(1) . . . 73(4) within region 46a. Because the layout and spacing of contacts in regions 46 a and 46 bare identical, absent some sort of indicia or mark on one of surfaces 44a or 44 b, the surfaces and contact layout on each of surfaces 44 a, 44b may look identical or at least substantially the same.

As mentioned above, connector 80 can be mated with a receptacleconnector that has a single set of contacts, not counting groundcontacts, on an interior surface. As an example, FIGS. 9A and 9B aresimplified diagrams that depict plug connector 80 mated with areceptacle connector 85 in two different possible mating orientations.Receptacle connector 85 includes a housing 86 that defines a cavity 87.Contacts 88(1) . . . 88(4) are positioned along a first interior surfaceof cavity 87 and ground contacts 88(a) and 88(b) are positioned on theside interior surfaces of the cavity. There are no contacts on a secondinterior surface opposite the first interior surface.

As shown in FIGS. 9A and 9B, when tab 44 of connector 80 is fullyinserted within cavity 87 each of contacts 73(1) . . . 73(4) aligns withand is in physical contact with one of contacts 88(1) . . . 88(4)regardless of which of the two possible orientations (referred to hereinas “up” or “down” for convenience but it is to be appreciated that theseare relative terms intended to connote a 180 degree change in theorientation of the connector only) connector 80 is inserted into cavity87. When connector 80 is inserted within cavity 87 with side 44 a up(FIG. 9A), contact 73(1) aligns with contact 88(1), contact 73(2) alignswith contact 88(2), contact 73(3) aligns with contact 88(3), and contact73(4) aligns with contact 88(4). When connector 80 is inserted withincavity 87 with side 44 b up (FIG. 9B), the contacts align differentlysuch that contact 73(4) aligns with contact 88(1), contact 73(3) alignswith contact 88(2), contact 73(2) aligns with contact 88(3), and contact73(1) aligns with contact 88(4). Additionally, when plug connector 80includes side ground contacts 73 a, 73 b, each side contact aligns withone of side ground contacts 88 a, 88 b from receptacle connector 85 ineither of the two possible insertion orientations as shown in FIGS. 9Aand 9B.

Thus, whether plug connector 80 is inserted into receptacle connector 85in either the “up” or “down” position, proper electrical contact can bemade between the contacts in the plug connector and the receptacleconnector. Some embodiments of the invention further pertain to anelectronic host device that includes a receptacle connector andcircuitry that switches the functionality of the receptacle connectorcontacts pins based on the insertion orientation of the plug connector.In some embodiments, a sensing circuit in the receptacle connector orthe host electronic device in which the receptacle connector is housed,can detect the orientation of the plug connector and set software and/orhardware switches to switch internal connections to the contacts in thereceptacle connector and properly match the receptacle connector'scontacts to the plug connector's contacts as appropriate. Details ofvarious embodiments of such circuitry are set forth in concurrentlyfiled and commonly-owned U.S. application Ser. No. ______ (AttorneyDocket No. 90911-825181), the contents of which are incorporated hereinin their entirety for all purposes.

In some embodiments the orientation of the plug connector can bedetected based on a physical orientation key (different from apolarization key in that an orientation key does not prevent the plugconnector from being inserted into the receptacle connector in multipleorientations) that, depending on the orientation of the plug connector,engages or does not engage with a corresponding orientation contact inthe receptacle connector. Circuitry connected to the orientation contactcan then determine which of the two possible orientations the plugconnector was inserted into the receptacle connector. In otherembodiments, orientation of the plug connector can be determined bydetecting a characteristics (e.g., voltage or current level) at one ormore of the contacts or by sending and receiving signals over one ormore of the contacts using a handshaking algorithm. Circuitry within thehost device that is operatively coupled to the receptacle connector canthen set software and/or hardware switches to properly match thereceptacle connector's contacts to the contacts of the plug connector.

While each contact in contact area 46 a of connector 80 is electricallyconnected to a contact directly opposite itself in contact area 46 b, inother embodiments, contacts in contact area 46 a can be electricallyconnected to contacts in contact in area 46 b that are not directlyopposite each other. FIGS. 10A-10C, which are similar to FIGS. 8A-8C anddepict a connector 90 having four contacts spaced identically to that ofconnector 80, are illustrative of one such an embodiment where eachcontact in contact area 46 a is connected to a corresponding contact incontact area 46 b that are spaced in a cater cornered relationship witheach other. As shown in FIG. 10A, the layout of contacts 73(1) . . .73(4) in contact region 46 a of connector 90 is identical to the layoutof the contacts in region 46 a of connector 80. In connector 90,however, contact 73(1) in contact area 46 a is electrically coupled to acorresponding contact in contact area 46 b, contact 73(1), that is onthe opposite side of centerplane 59 and spaced the same distance fromthe centerplane. Similarly, contacts 73(2), 73(3) and 73(4) in contactarea 46 a are each electrically coupled to a matching contact 73(2),73(3) and 73(4) in contact area 46 b located in a cater corneredrelationship on the opposite side of and spaced the same distance fromcenterline 59.

Electrical contact between contacts in a corresponding pair of contactsin connector 90 can be made in any appropriate way. In one embodiment,connections between matching contacts are made within the tab and/orbody of the connector. As one example, a PCB with contact pads printedon its upper and lower surfaces, one for each of contacts 73(1) . . .73(4) in each of regions 46 a and 46 b, can extend through the interiorof tab 44. A series of conductive lines, through holes and vias formedon the PCB can electrically connect each contact from contact region 46a to its matching connected contact in region 46 b according to theschematic in FIG. 10C.

Electrically connecting the contacts between surfaces 46 a and 46 b inthe manner shown in FIG. 10C provides the benefit that, regardless ofwhich of the two possible orientations connector 90 is mated with thereceptacle connector, the contacts in the receptacle connector alignwith the same contacts in connector 90. FIGS. 11A and 11B, which aresimplified diagrams showing connector 90 mated with receptacle connector85 in two different possible mating orientations, illustrate this aspectof the embodiment of FIG. 10C. In FIG. 11A, connector 90 is insertedwithin cavity 87 of connector 85 with side 44 a up. In this alignment,plug connector contact 73(1) is in physical contact with receptacleconnector contact 88(1), plug connector contact 73(2) is in physicalcontact with receptacle connector contact 88(2), plug connector contact73(3) is in physical contact with receptacle connector contact 88(3),and plug connector contact 73(4) is in physical contact with receptacleconnector contact 88(4).

As shown in FIG. 11B, when plug connector 90 is inserted withinreceptacle connector 85 with side 44 b up, the contacts align exactlythe same way. Thus, a receptacle connector 85 designed to mate withconnector 90 does not need to include circuitry that switches thecontacts based on the orientation of connector 90. Additionally, as withconnector 80, if connector 90 includes side contacts 73 a, 73 b, eachside contact aligns with one of the side contacts 88 a, 88 b regardlessof the insertion orientation.

In still other embodiments, some of individual contacts in contactregion 46 a can be connected to matching contacts in region 46 bdirectly opposite each other as shown in FIGS. 8A-8C, while otherindividual contacts in contact region 46 a can be connected to matchingcontacts in region 46 b positioned in a cater corner relationship toeach other as shown in FIGS. 10A-10C. For example, center contacts 73(2)and 73(3) can be connected together as shown in FIGS. 8A-8C while outercontacts 73(1) and 73(4) can be connected together as shown in FIGS.10A-10C.

To facilitate the dual orientation feature of certain embodiments of theinvention, some or all of the contacts within contact regions 46 a, 46 bof an connector can be arranged such that similarly purposed contactsare positioned within each of the contact regions in a mirroredrelationship with each other with respect to a plane 59 (center plane)that bisects the connector along the length of tab 44. For example,referring back to FIG. 8A, contact 73(1) is in a mirrored relationshipwith contact 73(4) as each contact is within the same row and is spacedthe same distance from plane 59 but on opposite sides of the centerplane. Similarly, contact 73(2) is in a mirrored relationship withcontact 73(3) with respect to center line 59. Similarly purposedcontacts are contacts that are designated to carry similar signals.Examples of similarly purposed contact pairs may include, first andsecond power contacts, left and right audio out contacts, first andsecond ground contacts, a pair of differential data contacts or twodifferential data contacts of the same polarity (e.g., two positive ortwo negative differential data contacts), a pair of serial transmit andreceive contacts, and/or other general first and second digitalcontacts.

The symmetrical mirrored relationship between similarly purposedcontacts within each of regions 46 a, 46 b ensures that for each pair ofsimilarly purposed contacts in a mirrored relationship, one of thesimilarly purposed contacts will be electrically connected to a contactin the receptacle connector that is either dedicated to the particularcontact or can be readily switched to the particular contact. This inturn simplifies the switching circuitry required within the receptacleconnector. As an example, where contacts 73(1) and 73(4) are similarlypurposed contacts that are dedicated to a pair of differential datasignals, when plug connector 80 is inserted into receptacle connector85, one of the differential data signal contacts will be in physicalcontact with receptacle contact 88(1) and the other of the differentialdata signal contacts will be in physical contact with receptacle contact88(4) regardless of whether the plug connector is mated with thereceptacle connector in an “up” or “down” insertion orientation. Thus,both the receptacle contacts 88(1) and 88(4) can be differential datacontacts (or can be operatively coupled via a switch or multiplexor tocircuitry that supports differential data contacts) ensuring that theywill be electrically coupled to a differential data contact in the plugconnector regardless of its insertion orientation. Switching circuitrywithin the receptacle connector thus does not need to take into accountthat a power contact or another contact that has internal connectionsvery different than those required by a differential data contact may beat one of the locations that aligns with contact 88(1) or 88(4).

While FIGS. 8A-8C and 10A-10C depict particular embodiments of theinvention with an even number of contacts in each of contact regions 46a and 46 b, some embodiments of the invention may include an odd numberof contacts in each of regions 46 a, 46 b. In such embodiments, one ofthe contacts on each side of the plug connector is a central contactthat is centered around bisecting plane 59 and thus aligns with acentrally located receptacle contact in both the “up” and “down”positions. The central contacts are not in a mirrored relationship (withrespect to centerline 59) per se with another contact, other than theleft and right halves of the center contact mirror each other, and thusare not paired with another similarly purposed contact in the same waythat other contacts might be.

FIGS. 12A-12C illustrate this aspect of certain embodiments of theinvention and depict a plug connector 99 that has three contacts 72(1) .. . 72(3) formed on the upper surface of tab 44 of the plug connectorthat are electrically connected to matching contacts on the lowersurface as with connector 80 and FIG. 8C. When connector 99 is insertedinto a corresponding receptacle connector 95 in an “up” position,contacts 72(1) . . . 72(3) align with contacts 98(1) . . . 98(3) of thereceptacle connector, respectively. When the connector is inserted intoreceptacle connector 80 in a “down” position, contacts 72(3) . . . 72(1)are reversed and align with contacts 98(1) . . . 98(3) of the receptacleconnector, respectively. In both orientations, plug connector contact72(2) aligns with central receptacle contacts 98(2). Also, in eachorientation, each of side contacts 72 a, 72 b align with side contacts98 a, 98 b.

Reference is now made to FIGS. 13A-13C which depict a dual orientationconnector 100 having eight contacts spaced apart in a single row in eachof contact regions 46 a and 46 b according to an embodiment of theinvention. FIG. 13A is a simplified perspective view of connector 100and FIGS. 13B and 13C are simplified top and bottom plan views,respectfully, of connector 100. As shown in FIG. 13A, connector 100includes a body 42 and a tab portion 44 that extends longitudinally awayfrom body 42 in a direction parallel to the length of the connector. Acable 43 is attached to body 42 at an end opposite of tab portion 44.

Tab 44 is sized to be inserted into a corresponding receptacle connectorduring a mating event and includes a first contact region 46 a formed ona first major surface 44 a and a second contact region 46 b (not shownin FIG. 13A) formed at a second major surface 44 b opposite surface 44a. Surfaces 44 a, 44 b extend from a distal tip of the tab to a spine109 that, when tab 44 is inserted into a corresponding receptacleconnector, abuts a housing of the receptacle connector or host devicethe receptacle connector is incorporated in. Tab 44 also includes firstand second opposing side surfaces 44 c, 44 d that extend between thefirst and second major surfaces 44 a, 44 b. In some embodiments, tab 44is between 5-10 mm wide, between 1-3 mm thick and has an insertion depth(the distance from the tip of tab 44 to spine 109) of between 5-15 mm.Also in some embodiments, tab 44 has a length that is greater than itswidth which is greater than its thickness. In other embodiments, thelength and width of tab 44 are within 0.2 mm of each other. In oneparticular embodiment, tab 44 is 6.7 mm wide, 1.5 mm thick and has aninsertion depth (the distance from the tip of tab 44 to spine 109) of6.6 mm. In other embodiments, tab 44 has the same 6.7 mm width and 1.5mm height but a longer length. Such embodiments may be particularlyuseful for mating with receptacle connectors with an opening in the sideof an electronic device that has a curved or otherwise highly stylizedenclosure. In such devices, the length of the tab can be increased by anamount that is determined by the slope of device enclosure and a heightof body 42. That is, tab 44 may have a length A to operate properly witha receptacle connector housed within an enclosure having a vertical edgeor face at the opening of the receptacle connector. However, to workproperly with a sloped device enclosure, an additional length B may beadded to compensate for the curvature of the device enclosure andadditional length C may be added to compensate for the thickness of plugconnector housing 42 to ensure that contacts within regions 46 a, 46 bare able to mate with contacts in the receptacle connector in the curvedenclosure just as they would in an enclosure having a flat or verticalface. As the curve of the enclosure becomes shallower, the value of Bmay be correspondingly increased. Similarly, as plug connector housing42 becomes thicker, the value of C may be increased.

The structure and shape of tab 44 is defined by a ground ring 105 thatis similar to ground ring 52 shown in FIG. 5C and can be made fromstainless steel or another hard conductive material. Ground ring 105also includes a flange portion or spine 109 that includes surface 109 aand 109 b that extend from the spine to the surfaces 44 a and 44 b,respectively, of the ground ring. Connector 100 includes retentionfeatures 102 a, 102 b formed as curved pockets in the sides of groundring 105 that do not extend to either of upper surface 44 a or lowersurface 44 b. Body 42, which is connected to ground ring 105 at spine109, is shown in FIG. 13A in transparent form (via dotted lines) so thatcertain components inside the body are visible. As shown, within body 42is a printed circuit board (PCB) 104 that extends into ground ring 105between contact regions 46 a and 46 b towards the distal tip ofconnector 100. One or more integrated circuits (ICs), such asApplication Specific Integrated Circuit (ASIC) chips 108 a and 108 b,can be operatively coupled to PCB 104 to provide information regardingconnector 100 and any accessory or device that connector 100 is part ofand/or to perform specific functions, such as authentication,identification, contact configuration and current or power regulation.

As an example, in one embodiment an ID module is embodied within an ICoperatively coupled to the contacts of connector 100. The ID module canbe programmed with identification and configuration information aboutthe connector and/or its associated accessory that can be communicatedto a host device during a mating event. As another example, anauthentication module programmed to perform an authentication routine,for example a public key encryption routine, with circuitry on the hostdevice can be embodied within an IC operatively coupled to connector100. The ID module and authentication module can be embodied within thesame IC or within different ICs. As still another example, inembodiments where connector 100 is part of a charging accessory, acurrent regulator can be embodied within one of IC's 108 a or 108 b. Thecurrent regulator can be operatively coupled to contacts that are ableto deliver power to charge a battery in the host device and regulatecurrent delivered over those contacts to ensure a constant currentregardless of input voltage and even when the input voltage varies in atransitory manner.

Bonding pads 110 can also be formed within body 42 near the end of PCB104. Each bonding pad can be connected to a contact or contact pairwithin regions 46 a and 46 b. Wires (not shown) within cable 43 can thenbe soldered to the bonding pads to provide an electrical connection fromthe contacts to the accessory or device that connector 100 is associatedwith. Generally, there is one bonding pad and one wire within cable 43for each set of electrically independent contacts (e.g., a pair ofmatching connected contacts, one in region 46 a and one in region 46 bthat are electrically coupled to each other through PCB 104) ofconnector 100. Additionally, one or more ground wires (not shown) fromcable 43 can also be soldered or otherwise connected to ground ring 105for a ground signal.

As shown in FIGS. 13B, 13C, eight external contacts 106(1) . . . 106(8)are spaced apart along a single row in each of contact regions 46 a, 46b. Each contact in contact region 46 a is electrically connected to acorresponding contact in contact region 46 b on the opposite side of theconnector. Contacts 106(1) . . . 106(8) can be used to carry a widevariety of signals including digital signals and analog signals as wellas power and ground as previously discussed. In one embodiment, eachcontact 106(1) . . . 106(8) has an elongated contact surface. In oneembodiment the overall width of each contact is less than 1.0 mm at thesurface, and in another embodiment the width is between 0.75 mm and 0.25mm. In one particular embodiment, a length of each contact 106(i) is atleast 3 times as long at the surface than its width, and in anotherembodiment a length of each contact 106(i) is at least 5 times as longat the surface than its width.

FIG. 14A depicts one particular implementation of a pinout 106 a forplug connector 100 according to one embodiment of the invention. Pinout106 a includes eight contacts 106(1) . . . 106(8) that can correspond tothe contacts in FIGS. 13A-13C. Each of contacts 106(1) . . . 106(8) inpinout 106 a are mirrored contacts meaning an individual contact 106(i)is coupled to another contact 106(i) directly opposite itself on theopposing side of the connector. Thus, each of contacts 106(1) . . .106(8) is in a mirrored relationship with an identical contact, whichfor convenience is represented by the same reference number as itscounterpart or mirrored contact.

As shown in FIG. 14A, pinout 106 a includes two contacts 106(4), 106(5)that are electrically coupled together to function as a single contactdedicated to carrying power; first and second accessory contacts 106(1)and 106(8) that can be used for an accessory power signal and anaccessory ID signal, and four data contacts 106(2), 106(3), 106(6) and106(7). There is no dedicated contact for ground in any of contacts106(1) . . . 106(8) on the upper or lower surfaces of the connector.Instead, ground is taken between the ground ring (not shown in FIG. 14A)and contacts in the side of the corresponding receptacle connector asdiscussed above.

Power contacts 106(4), 106(5) can be sized to handle any reasonablepower requirement for a portable electronic device, and for example, canbe designed to carry between 3-20 Volts from an accessory to charge ahost device connected to connector 100. Power contacts 106(4), 106(5)are positioned in the center of contact regions 46 a, 46 b to improvesignal integrity by keeping power as far away as possible from the sidesof ground ring 105.

Accessory power contact 106(1) can be used for an accessory power signalthat provides power from the host to an accessory. The accessory powersignal is typically a lower voltage signal than the power in signalreceived over contacts 106(4) and 106(5), for example, 3.3 volts ascompared to 5 volts or higher. The accessory ID contact provides acommunication channel that enables the host device to authenticate theaccessory and enables the accessory to communicate information to thehost device about the accessory's capabilities as described in moredetail below.

Data contacts 106(2), 106(3), 106(6) and 106(7) can be used to enablecommunication between the host and accessory using one or more ofseveral different communication protocols. In some embodiments, datacontacts 106(2) and 106(3) operate as a first pair of data contacts anddata contacts 106(6), 106(7) operate as a second pair of data contactsallowing two different serial communication interfaces to be implementedover the data contacts as discussed below. In pinout 106 a, datacontacts 106(2), 106(3) are positioned adjacent to and on one side ofthe power contacts, while data contacts 106(6) and 106(7) are positionedadjacent to but on the other side of the power contacts. The accessorypower and accessory ID contacts are positioned at each end of theconnector. The data contacts can be high speed data contacts thatoperate at rate that is at least two orders of magnitude faster than anysignals sent over the accessory ID contact which makes the accessory IDsignal look essentially like a DC signal to the high speed data lines.Thus, positioning the data contacts between the power contacts and theID contact improves signal integrity by sandwiching the data contactsbetween contacts designated for DC signals or essentially DC signals.

FIG. 14B depicts an implementation of a pinout 106 b for plug connector100 according to another embodiment of the invention. Similar to pinout106 a, pinout 106 b also includes eight contacts 106(1) . . . 106(8) oneach side of connector 100 that can correspond to the contacts in FIGS.13A-13C. Pinout 106 a differs from pinout 106 b in that some of thecontacts are mirrored contacts while other contacts are in a catercorner relationship with each other across either a centerline 59 of theconnector or across one of two quarter lines 59 a, 59 b of the connectoras described below (as used herein, the term “quarter line” does notencompass the centerline). Also, pinout 106 a includes a single powercontact instead of two power contacts on each side of the connector andadds a dedicated ground contact.

Specifically, as shown in FIG. 14B, pinout 106 b includes a first pairof mirrored data contacts 106(2), 106(3) and a second pair of mirroreddata contacts 106(6) and 106(7) where each individual mirrored datacontact is electrically connected to a corresponding data contactdirectly opposite itself on the opposing side of the connector. Thepower contact 106(5) includes two contacts positioned in a cater cornerrelationship with each other across centerline 59, while the groundcontact 106(1) includes two contacts positioned in a cater cornerrelationship with each other across centerline 59. The accessory powercontact 106(4) and accessory ID contact, on the other hand, arepositioned in a cater corner relationship with counterpart contactsacross quarter lines 59 a and 59 b, respectively. When connector 100includes the pinout 106 b, one side of connector 100 may have contacts106(1) . . . (8) ordered sequentially as shown in FIG. 14B, while andthe other side of connector 100, includes contacts ordered as follows:106(1), 106(7), 106(6), 106(8), 106(5), 106(3), 106(2), 106(4) whereeach individual contact 106(i) is electrically coupled to a contacthaving the same reference number on the opposite side of the connectoras shown in FIG. 14B.

Power contact 106(5) can be sized to handle any reasonable powerrequirement for a portable electronic device, and for example, can bedesigned to carry between 3-20 Volts from an accessory to charge a hostdevice connected to connector 100. Ground contact 106(8) provides adedicated ground contact at one end of the row of contacts as far awayas possible from power contact 106(5). Ground in pinout 106 b is alsoprovided through the ground ring 105 via contacts in the side of thecorresponding receptacle connector as with pinout 106 a. The additional,dedicated ground contact 106(1), however, provides additional groundcoverage and provides a benefit in that the contact integrity of groundpin 106(1) can be specifically designed to carry the electrical groundsignal (e.g., using gold plated copper contacts) without beingconstrained by the hardness or other requirements associated with thecontacts in the side of ground ring 105 that ensure the ground ring issufficiently robust to withstand multiple thousands of use cycles.

Data contacts 106(2), 106(3), 106(6) and 106(7) in pinout 106 b can beidentical to the data contacts discussed with respect to pinout 106 a.In pinout 106 b, each pair of data contacts 106(2), 106(3) and 106(6),106(7) is positioned between either power contact 106(5) or groundcontact 106(1), each of which carries a DC signal, and one of theaccessory power or accessory ID contacts 106(4) and 106(8),respectively, which carry either an accessory power signal (a DC signal)or a relatively low speed accessory ID signal. As discussed above, thedata contacts can be high speed data contacts that operate at rate thatis at least two orders of magnitude faster than the accessory ID signalsmaking it look essentially like a DC signal to the high speed datalines. Thus, positioning the data contacts between either the powercontacts or ground contacts and the ACC contacts improves signalintegrity by sandwiching the data contacts between contacts designatedfor DC signals or essentially DC signals.

In one embodiment, pinout 106 a represents the signal assignments of aplug connector 100 in a plug connector/receptacle connector pairing thatcan be the primary physical connector system for an ecosystem ofproducts that includes both host electronic devices and accessorydevices. In another embodiment, pinout 106 b represents such signalassignments. Examples of host devices include smart phones, portablemedia players, tablet computers, laptop computers, desktop computers andother computing devices. An accessory can be any piece of hardware thatconnects to and communicates with or otherwise expands the functionalityof the host. Many different types of accessory devices can bespecifically designed or adapted to communicate with the host devicethrough connector 100 to provide additional functionality for the host.Plug connector 100 can be incorporated into each accessory device thatis part of the ecosystem to enable the host and accessory to communicatewith each other over a physical/electrical channel when plug connector100 from the accessory is mated with a corresponding receptacleconnector in the host device. Examples of accessory devices includedocking stations, charge/sync cables and devices, cable adapters, clockradios, game controllers, audio equipment, memory card readers,headsets, video equipment and adapters, keyboards, medical sensors suchas heart rate monitors and blood pressure monitors, point of sale (POS)terminals, as well as numerous other hardware devices that can connectto and exchange data with the host device.

It can be appreciated that some accessories may want to communicate withthe host device using different communication protocols than otheraccessories. For example, some accessories may want to communicate withthe host using a differential data protocol, such as USB 2.0, whileother accessories may want to communicate with the host using anasynchronous serial communication protocol. In one embodiment datacontacts 106(2), 106(3), 106(6) and 106(7) can be dedicated to two pairsof differential data contacts, two pairs of serial transmit/receivecontacts, or one pair of differential data contacts and one pair ofserial transmit/receive contacts depending on the purpose of connector100 or function of the accessory connector 100 is part of. As an examplethat is particularly useful for consumer-oriented accessories anddevices, the four data contacts can accommodate two of the followingthree communication interfaces: USB 2.0, Mikey Bus or a universalasynchronous receiver/transmitter (UART) interface. As another examplethat is particularly usefully for debugging and testing devices, the setof data contacts can accommodate two of either USB 2.0, UART or a JTAGcommunication protocols. In each case, the actual communication protocolthat is used to communicate over a given data contact can depend on theaccessory as discussed below.

As mentioned above, connector 100 may include one or more integratedcircuits that provide information regarding the connector and anyaccessory or device it is part of and/or perform specific functions. Theintegrated circuits may include circuitry that participates in ahandshaking algorithm that communicates the function of one or morecontacts to a host device that connector 100 is mated with. For example,an ID module can be embodied within IC 108 a as discussed above andoperatively coupled to the ID contact, contact 106(8) in each of pinouts106 a and 106 b, and an authentication module can be embodied in IC 108a with the ID module or in a separate IC, such as IC 108 b. The ID andauthentication modules each include a computer-readable memory that canbe programmed with identification, configuration and authenticationinformation relevant to the connector and/or its associated accessorythat can be communicated to a host device during a mating event. Forinstance, when connector 100 is mated with a receptacle connector in ahost electronic device, the host device may send a command over itsaccessory ID contact (that is positioned to align with the ID contact ofthe corresponding plug connector) as part of a handshaking algorithm todetermine if the accessory is authorized to communicate and operate withthe host. The ID module can receive and respond to the command bysending a predetermined response back over the ID contact. The responsemay include information that identifies the type of accessory or devicethat connector 100 is part of as well as various capabilities orfunctionalities of the device. The response may also communicate to thehost device what communication interface or communication protocol theconnector 100 employs on each of data contact pairs 106(2),106(3) and106(6), 106(7). If connector 100 is part of a USB cable, for example,the response sent by the ID module may include information that tellsthe host device that contacts 106(2) and 106(3) are USB differentialdata contacts. If connector 100 is a headset connector, the response mayinclude information that tells the host that contacts 106(6) and 106(7)are Mikey Bus contacts. Switching circuitry within the host can thenconfigure the host circuitry operatively coupled to the contacts in thereceptacle connector accordingly as discussed below.

During the handshaking routine the authentication module can alsoauthenticate connector 100 (or the accessory it is part of) anddetermine if connector 100 (or the accessory) is an appropriateconnector/accessory for the host to interact with using any appropriateauthentication routine. In one embodiment authentication occurs over theID contact prior to the identification and contact switching steps. Inanother embodiment authentication occurs over one or more of the datacontacts after they are configured according to response sent by theaccessory.

FIGS. 15A and 15B depict one embodiment of a receptacle connector 140according to the invention that can be included in a host device toenable an accessory having a connector 100 to be physically coupled tothe host device. As shown in FIGS. 15A, 15B, receptacle connector 140includes eight contacts 146(1) . . . 146(8) that are spaced apart in asingle row. In one embodiment, receptacle connector 140 the pinout ofcontacts 146(1) . . . 146(8) is compatible with a plug connector havingpinout 106 a, and in another embodiment the pinout of contacts 146(1) .. . 146(8) is compatible with a plug connector having pinout 106 b. Thecontacts are positioned within a cavity 147 that is defined by a housing142. Receptacle connector 140 also includes side retention mechanisms145 a, 145 b that engage with retention features 102 a, 102 b inconnector 100 to secure connector 100 within cavity 147 once theconnectors are mated. Retention mechanisms 145 a, 145 b can be, forexample springs, and can be made from an electrically conductivematerial to double as ground contacts. Receptacle connector 140 alsoincludes two contacts 148(1) and 148(2) (sometimes referred to as“connector detect” contacts) that are positioned slightly behind the rowof signal contacts and can be used to detect when connector 100 isinserted within cavity 140 and detect when connector 100 exits cavity140 when the connectors are disengaged from each other.

In one embodiment, receptacle connector 140 has a pinout as shown inFIG. 15C that matches pinout 106 a and in another embodiment receptacleconnector 140 has a pinout as shown in FIG. 16B that matches pinout 106b. In each of FIGS. 15C and 15D, the ACC1 and ACC2 pins are configuredto mate with either the accessory power or accessory ID pins of the plugconnector depending on the insertion orientation of plug connector, thepair of Data A contacts is configured to mate with either the pair ofData 1 contacts or the pair of Data 2 contacts of the plug connector,and the P_IN (power in) pin or pins are configured to mate with thePower contact or contacts of the plug connector. Additionally, in thepinout of FIG. 15D, the GND contact is configured to mate with the GNDcontact in the plug connector.

Reference is now made to FIGS. 16A-16K, which show simplified sectionalviews of plug connector 100 associated with an accessory device (notshown) being mated with receptacle connector 140 incorporated into ahost electronic device (the housing or enclosure of which is partiallyshown in each figure). Each time a user interacts with an accessorydevice or host electronic device, the user may make an evaluationregarding its quality. Such an interaction may occur when a user insertsa plug connector, such as connector 100 into a corresponding receptacleconnector, such as receptacle connector 140. If the plug connector iseasy to insert into the receptacle connector, the user may gain theimpression that the electronic device that includes connector 100 orconnector 140 is of high quality, and that the company that manufacturedthe electronic device is a company of quality as well that can betrusted to manufacture reliable devices. Also, such ease of insertionmay improve the user's experience and simply make the device moreenjoyable to use.

Accordingly, embodiments of the present invention may provide plugconnectors and receptacle connectors openings that provide for the easyinsertion of the plug connector into the receptacle connector. Anexample is shown in FIG. 16A, which is a simplified top view of plugconnector 100 and receptacle connector 140 in alignment with each otherprior to a mating event according to an embodiment of the invention. Inthis example, plug connector 100 may have a curved leading edge 101.Leading edge 101 may be rounded for approximately 1 mm of its length ateach of its ends as shown by distance L₁, and in some embodiments isrounded for between 0.5 mm and 1.5 mm at each end. This rounded frontend may make it easier to insert plug connector 100 into receptacleconnector 140 when the plug connector is rotated off axis, that is, whenthe plug connector is inserted at an incorrect pitch angle. Also in thisexample, a multi-tiered opening may be provided by the device enclosure(and its associated parts) to receptacle connector 140 into which plugconnector 100 is inserted. The multi-tiered opening may make it easierto insert the plug connector into the receptacle when the plug connectoris inserted either too far left or too far right of the opening in the Xdirection.

In this specific example, an opening of receptacle connector 140 may beformed by an edge of a trim ring 492 that cooperates with receptaclehousing 142 to form an insertion cavity into which plug connector 100 isinserted during a mating event. Trim ring 492, which can be connected tothe device enclosure 490 at a location not shown in FIG. 16A, may havechamfered leading edges 494. Receptacle housing 142 may be offset behindtrim ring 492, and may have an angled surface 495 at the sides of trimring 492 that further narrows the insertion cavity. In some embodimentschamfered edges 494 and angled surfaces 495 are each angled between30-60 degrees and in one embodiment are angled at approximately 45degrees. Also, in some embodiments chamfered edges 494 are between 0.1and 0.5 mm wide and angled surfaces 495 are between two and four timesthe width of chamfered edges 494. In one particular embodiment,chamfered leading edges are chamfered by approximately 0.3 mm and angledsurfaces 495 narrow the opening of the insertion cavity by approximately1 mm on each side of the trim ring. Thus, in this embodiment, themulti-tiered opening may provide a 2.6 mm tolerance in the placement ofplug connector 100 relative to the opening of receptacle connector 140.This relatively large tolerance (given the overall width of 6.6 mm forthe plug connector) combined with the curved edges of plug connector100, may make it relatively easy for a user to insert the plug connectorinto the receptacle connector. Again, this ease of insertion may informa user's opinion as to the quality of the accessory device and/or hostelectronic device.

FIG. 16B is a simplified cross-sectional view of plug connector 100 andreceptacle connector 140 in the same alignment position with each otherprior to a mating event shown in FIG. 16A. As the plug connector isinserted into cavity 147 of the receptacle connector the first point ofcontact between the two connectors will be ground ring 105 contactingmetal trim ring 492, which surrounds the opening to cavity 147 and isgrounded. Thus, any static charge that has built up on the plugconnector can be discharged upon contact with the trim ring. As the plugconnector is inserted further into cavity 147, different portions of theplug connector may first come into contact with or engage with variousportions of the receptacle connector as shown in FIGS. 16C-K. Forexample, FIG. 16C depicts the respective positions of the two connectorswhen individual contacts 106(i) may come in contact with trim ring 492.In one embodiment, this is approximately 1.5 mm after leading edge 101of connector 100 has entered cavity 147 or 6.35 mm from a fully matedposition. FIG. 16D depicts the respective positions of the twoconnectors when individual contacts 106(i) may last contact the trimring. In one embodiment, this is approximately 4.1 mm after leading edge101 of connector 100 has entered cavity 147 or 3.75 mm from a fullymated position.

FIGS. 16D and 16F each depict connector 100 at a position prior to plugconnector contacts 106 coming into physical contact with receptacleconnector contacts 146. As shown in FIGS. 16D and 16E, each receptacleconnector contact 146(i) includes a tip 146 a, a beam portion 146 b andan anchor portion 146 c. Plug connector contacts 106 are wipingcontacts, that is each contact 106(i) moves laterally with a wipingmotion across the tip 146 a of its respective contact 146(i) during amating event until settling into a fully mated position where a centralportion of the contact surface of contact 106(i) is in physical contactwith tip 146 a of receptacle contact 146(i). The process in which thecontacts of a plug connector and receptacle first come in contact witheach other causes wear and tear on the contacts that may result indegraded performance after thousands of repeated use cycles. Embodimentsof the invention have designed the contacts to reduce such wear and tearand thus improve device lifetime. To better understand this aspect ofcertain embodiments of the invention, reference is made to FIG. 16E,which is an exploded view of the portion of FIG. 16D shown in dottedlines.

As shown in FIG. 16E, the interface between leading edge 101 and top andbottom surfaces 105 a and 105 b of connector 100 may form edges 101 aand 101 b, respectively. As plug connector 100 is inserted further intoreceptacle connector 140, edge 101 a (or edge 101 b if the connector isinserted in a reversed orientation) of contact 106(i) may engage or comeinto contact with receptacle contact 146(i) as shown in FIG. 16G.Embodiments of the invention may form surfaces 103 a, 103 b of groundring 105 such that edge 101 a is located at a height Z that reduces wearof receptacle contact 106(i) and improves device lifetime. Specifically,as surfaces 103 a, 103 b are angled more steeply, height Z may increase.This, in turn, may cause edges 101 a, 101 b to engage contact 146(i)near top surface or tip 146 a. But when plug connector 100 is engaged inreceptacle connector 140, contact 106(i) on the plug connector may matewith receptacle contact 146(i) at top surface 146 a (as shown in FIG.16K). Accordingly, if surfaces 103 a, 103 b are sloped too sharply,edges 101 a, 101 b may wear the metallic plating near the tip 146 a ofreceptacle contact 146(i), which may degrade electrical connectionsbetween connector insert contact 106(i) and connector receptacle contact146(i).

It should be noted that a large height Z could be accommodated for byincreasing a height of receptacle contact 146(i). But this would requirea larger deflection of receptacle contact 146(i) during insertion of theplug connector. A larger deflection of receptacle contact 146(i) mayrequire a longer contact beam and resulting greater receptacle length inthe insertion direction of cavity 147 to avoid fatigue and cold-workingof receptacle contact 146(i). Conversely, when Z is too small, edges 101a, 101 b may encounter contact 146(i) at a location much lower than topsurface 146 a, shown in this example as location 146 d. Engaging contact146(i) at location 146 d may increase the force placed upon receptaclecontact 146(i) during insertion of the plug connector, therebyincreasing the wear to the plating of contact 146(i). Thus, embodimentsof the present invention may provide a ground ring 105 having edges 101a, 101 b that are positioned to engage connector receptacle contacts 146at a location away from top surface 146 a in order to protect plating atthis mating point. Edges 101 a, 101 b may further be positioned to avoidexcessive force being imparted to receptacle connector contacts 146during the insertion of the plug connector.

Turning now to FIGS. 16F and 16H, prior to any of contacts 106 cominginto electrical contact with contacts 146, ground ring 105 comes intocontact with latches 145 a, 145 b, which also act as ground contacts(FIG. 16F) and later each of contacts 146 slide past the interfacebetween the front portion of ground ring 105 and the beginning of one ofcontact regions 46 a, 46 b (FIG. 16H). In one particular embodiment,initial contact with latches 145 a, 145 b occurs 2.6 mm from a fullymated position and contacts 146 first touch the dielectric material inone of contact regions 46 a, 46 b 1.4 mm from a fully mated position.Then, as shown in FIG. 16I, just 0.2 mm after contacts 146 are no longerin physical contact with ground ring 105 (1.2 mm from a fully matedposition), connector 100 contact connector detect contacts 148(1) and148(2), and just 0.4 mm later, plug connector contacts 106 begin to comeinto contact with receptacle connector contacts 146 and a fully matedposition is achieved 0.8 mm later.

FIG. 16K depicts the completion of a mating event between the plug andreceptacle connectors where plug connector 100 is fully inserted withincavity 147 of the receptacle connector 140. In the fully mated position,each of contacts 106(1) . . . 106(8) from one of contact regions 46 a or46 b are physically coupled to one of contacts 146(1) . . . 146(8)depending on the insertion orientation of connector 100 with respect toconnector 140. Thus, when plug connector 100 has pinout 106 a, contact146(1) will be physically connected to either contact 106(1) or 106(8)depending on the insertion orientation; data contacts 146(2), 146(3)will connect with either data contacts 106(2), 106(3) or with datacontacts 106(7), 106(6) depending on the insertion orientation, etc.

Prior to a mating event, the host will generally not know the insertionorientation of plug connector 100 or what communication protocol will betransmitted over data contacts 106(2), 106(3), 106(6) and 106(7).Switching circuitry within the host device includes switches thatoperatively connect circuitry on the host side necessary to supportsignals and communication interfaces used by the contacts of connector100 to the receptacle connector contacts 146(1) . . . 146(8) asappropriate. FIG. 17 depicts one embodiment of switching circuitry 150configured to allow a host device to implement pinout 106 a shown inFIG. 14A. Switching circuitry 150 includes switches 151 and 158 that areoperatively coupled to receptacle contacts 146(1) and 146(8),respectively, and switches 152, 153, 156 and 157 that are operativelycoupled to contacts 146(2), 146(3), 146(6) and 146(7), respectively. Inone embodiment, switches are not required for contacts 146(4) and 146(5)as, regardless of the insertion orientation, these contacts always alignwith power contacts 106(4) and 106(5) in pinout 106 a which areelectrically connected to each other. In another embodiment, there is aswitch 151-158 for each of contacts 146(1) . . . 146(8) and the switchis initially in an open state until circuitry connected to contacts148(1), 148(2) detects that connector 100 has been fully inserted withinthe receptacle connector and the accessory is authorized to operate withthe host at which time the switches connect the circuitry as describedbelow.

Each of switches 151 and 158 enables circuitry that provides anaccessory power signal to a receptacle connector contact to be switchedonto either contact 146(1) or 146(8) depending on the insertionorientation of plug connector 100. Additionally, some embodiments of theinvention allow data signals (e.g., a pair of UART transmit and receivesignals or JTAG clock signals) to be transmitted over contacts 146(1),146(8). Switches 151 and 158 can also operatively connect the circuitryrequired to implement such UART or JTAG communication to contacts146(1), 146(8) as determined during the handshaking routine and/orcommunicated by connector 100. Similarly, each of switches 152, 153, 156and 157 switch the necessary circuitry to support communicationinterfaces USB 2.0, Mikey Bus or UART onto contacts 152, 153, 156, and157 as instructed by connector 100.

Switching circuitry 150 also allows the communication interface employedby the data contacts to be dynamically switched while connector 100 iscoupled to a host device. The dynamic switching can be initiated, forexample, by a message sent from the ID module within the accessory tothe host device over contact 106(8) informing the host that a newcommunication interface will be used on the contacts. As an example, inresponse to an initial handshaking sequence when connector 100 is matedwith a corresponding connector on the host device, the ID module maysend a response informing the host that data contacts 106(2), 106(3) and106(6), 106(7) are used for two pairs of USB 2.0 differential datacontacts. As some point later during operation of the accessory thatconnector 100 is incorporated into, the accessory may require the use ofa UART serial interface to communicate with the host device over thesame two contacts previously dedicated for USB signals. To do so, theaccessory sets internal switches coupled to contacts 106(6), 106(7) thatswitches the contacts from being operatively coupled to USB circuitry inthe accessory to instead be coupled to UART circuitry and sends amessage to host 100 noting the new configuration of contacts 106(6),106(7).

As previously stated, many different types of accessories may employplug connector 100 to physically couple to and communicate with a hostdevice that includes a receptacle connector 140. FIGS. 18-28 provideseveral specific examples of such accessories. FIG. 18 is a simplifiedperspective view of a USB charger/adapter 160 according to an embodimentof the invention. USB adapter 160 includes an eight contactdual-orientation inline connector 162 at one end and a USB maleconnector 164 at the other end. An optional cable 163 couples connector162 to connector 164, in other embodiments both connectors 162 and 164extend from opposite sides of a single compact housing. Connector 162can have the same physical form factor as connector 100 shown in FIG.13A and includes contacts 166(1) . . . 166(8) that correspond in sizeand shape to contacts 106(1) . . . 106(8).

USB charger/adapter 160 is specifically adapted to be used in datasynchronization applications and charging applications. To this end,connector 162 includes two USB 2.0 differential data contacts atlocations where the pair of differential data contacts, Data 1, arelocated (locations 166(2), 166(3)). FIGS. 19A and 19B depict twodifferent pinouts of USB charger 160 where the pinout in FIG. 19A iscompatible with pinout 160 a and the pinout in FIG. 19B is compatiblewith pinout 160 b. As shown in FIG. 20, the USB contacts are coupledthrough ESD protection circuitry 169 to the USB contacts in connector164. Connector 162 also includes power contact(s) coupled to a currentregulator 168 b to provide a power out signal from the V_(Bus) line ofUSB connector 164 that can be used to charge the host device. Theaccessory ID contact is connected to an ID module 168 a within connector162 to enable an initial handshaking routine between the connector andits host. A memory within ID module 168 a stores information thatinforms the host that contacts 166(2), 166(3) are dedicated for USB 2.0differential data signals.

Adapter 160 also includes an authentication module (not shown) toauthenticate the adapter to the host as discussed above with respect toFIG. 14. In one embodiment the authentication module is embodied withinID module 168 a and authenticates adapter 160 over the ID contact. Inanother embodiment the authentication module is connected to datacontacts 166(2), 166(3) and authenticates the adapter over thesecontacts after the handshaking routine between the host and ID moduleoperatively connects USB circuitry within the host connected to thereceptacle contacts that align with contacts 166(2) and 166(3). Groundis provided at the sides of connector 162 via contacts in the side ofthe ground ring, and in the embodiment of FIG. 19B at ground contact166(1). Since the USB adapter does not require other data signals nordoes it require power to be delivered to it from the host, contacts foraccessory power and for the second data pair, Data 2 are not requiredand, in some embodiments are left unconnected to circuitry. Asconfigured, connector 520 allows for USB 2.0 synchronization as well as5 volt, 2 amp charging when USB connector 164 is coupled to a charger165.

FIG. 21 is a simplified perspective view of a docking station 170 thatincludes a plug connector 172 according to an embodiment of theinvention similar to connector 100 discussed in FIGS. 13A-C and 14.Connector 172 extends upward from a surface 173 upon which a portableelectronic device may be placed when docked in station 170. When docked,tab 172 is mated with a receptacle connector incorporated into theportable media device and a second surface 174 can support a back of theelectronic device. The ID contact of connector 172 is connected to an IDmodule within the connector to inform the host that two of the datacontacts are dedicated for USB 2.0 differential data signals. Dockingstation 170 also includes an authenticate module that can authenticatethe docking station to its host as discussed with respect to USP adapter160. The docking station can charge the portable media device over thetwo centrally located power contacts that are coupled together andcoupled to current regulator to provide a power out signal. Ground isprovided at the sides of connector via contacts in the side of theground ring.

Docking station 170 allows a portable media device, such as an iPod orMP3 player or an iPhone or other smart phone to be connected to acomputer via connector 172. In one embodiment, connector 172 supportsthe full complement of eight contacts set forth in FIGS. 16A and 16B anddocking station 170 can connect to the computer with a USB cable. Inanother embodiment the docking station includes a receptacle connectorhaving the same pinout as connector 140 and can connect to a computeralso having a receptacle connector 140 with a cable adapter thatincludes two plug connectors 100 coupled together via a cable.

FIG. 22 is a simplified top plan view of a video adapter 180 accordingto an embodiment of the invention. Video adapter 180 includes a plugconnector 182 similar to connector 100 discussed in FIGS. 13A-C. Thepinout of adapter 180, shown in FIGS. 23A (for a version compatible withpinout 160 a) and 23B (for a version compatible with pinout 160 b),includes one set of USB 2.0 differential data contacts and a set of UARTtransmit/receive contacts. The accessory ID contact is coupled to an IDmodule 188 a within the connector that includes a memory that storesinformation to inform the host that two of the data contacts arededicated for USB 2.0 communication while the other two data contactsare dedicated to UART signals. In one embodiment one of the sets of datacontacts (either the USB or UART contacts) can be connected to anauthentication module 188 c to authenticate adapter 180, while inanother embodiment the authentication module is connected to the IDcontact along with the ID module as discussed above with respect toother accessories.

Adapter 180 includes an adapter housing 184 within which is a videoconnector 185 a for any suitable format of video signal. In oneembodiment video connector 185 a is an HDMI receptacle connector, inanother embodiment connector 185 a is a VGA receptacle connector, and instill another embodiment connector 185 a is a component video connector.A video processor 187 (shown in FIG. 24) separates audio and video datasent over connector 182 in USB 2.0 format and converts the data to theappropriate format for output over connector 185 a.

In some embodiments video adapter 180 also includes a receptacleconnector 185 b that includes the same pinout and physical form factoras connector 140. Any plug connector that can mate with connector 140could also mate with connector 185 b. Connector 185 b enables otheraccessories to be coupled to the same host device that connector 182 iscoupled with via a cascaded connection. A controller 188 is coupled toconnector 185 b and provides all the functionality (authentication,contact switching, etc.) that the host device provides with respect toconnector 140. Thus, controller 188 can set the eight contacts ofconnector 185 b in the same manner that the switching circuitry 150 canset contacts 146(1) . . . 146(8). Power boosting circuitry 189 booststhe accessory power signal received from the host device over contact186(4) and provides the signal as a power out signal through controller188 to the appropriate contact in connector 185 b. Additionally, in thisembodiment adapter 180 can provide power regulated by current regulator188 b to the host device over the power contacts (contacts 186(4) and186(5) in the embodiment of FIG. 23A or contact 186(5) in the embodimentof FIG. 23B) when connector 185 b is connected to an accessory or otherdevice that enables charging.

FIG. 25 a simplified top plan view of a SD (secure digital) card adapter190 according to an embodiment of the invention. SD card adapter 190includes a plug connector 192 similar to connector 100 discussed inFIGS. 13A-C and a housing 194. Housing 194 and plug connector 192 areconnected by a cable 193. As shown in FIG. 27, within housing 194 is anSD card reader 195, a microcontroller 197, an SD card interface 198 anda power converter 199 that is operatively coupled to convert the powerprovided by the host over contact 196(4) to a 3 volt power out signalthat is provided to an appropriate contact on the SD card reader.

The pinout of connector 192 includes one set of USB 2.0 differentialdata contacts and one set of UART transmit/receive contacts as shown ineach of FIGS. 26A (for a version compatible with pinout 160 a) and 26B(for a version compatible with pinout 160 b). Power contacts (contacts196(4) and 196(5) in the embodiment of FIG. 26A or contact 196(5) in theembodiment of FIG. 26B) are not used. The ID contact is coupled to an IDmodule 198 a that includes a memory that stores information to informthe host that two of the data contacts are dedicated for USB 2.0communication while the other two data contacts are dedicated to UARTsignals. In one embodiment one of the sets of data contacts (either theUSB or UART contacts) can be connected to an authentication module 198 cto authenticate adapter 190, while in another embodiment theauthentication module is connected to the ID contact along with the IDmodule as discussed above with respect to other accessories. SD cardinterface 198 is coupled to SD card reader 195 to read data stored on anSD card inserted within the card read and transmits the data to the hostdevice over the two USB data contacts under the control ofmicrocontroller 197.

In another embodiment of the invention, a camera adapter is providedthat is similar to SD card adapter 190 but connects to a camera over aUSB connection. This embodiment includes a USB connector instead of anSD card reader and also provides power boosting circuitry to supply a 5volts out signal over the USB power contact. The USB camera adapter doesnot include an SD card interface and instead buffers data receiveddirectly over the camera's USB contacts and provides the data to thehost via the two USB data contacts.

FIG. 28A is a simplified schematic representation of an adapter 200according to an embodiment of the invention. Adapter 200 includes anexternal contact plug connector 202 and a receptacle connector 205 eachof which include multiple contacts that can accommodate some or all ofvideo, audio, data and control signals along with power and ground. Plugconnector 202 is compatible with a receptacle connector 216 of a hostdevice 215 that can be, for example, a portable media player. Receptacleconnector 205 is compatible with a plug connector 222 of an accessory220, which is shown to be a docking station/clock radio but can be anyelectronic accessory that includes a plug connector that can be coupledto adapter 200. Plug connector 222 is incompatible with receptacleconnector 216 (and thus receptacle connector 205 is also incompatiblewith plug connector 202). The incompatibility may be either a physicallyincompatibility between the two connectors (e.g., plug connector 222 hasa size or shape that does not enable it to be mated with connector 216)or an electrical incompatibility (i.e., even though plug connector 22can be physically connected to receptacle connector 216, the connectorscarry one or more signals or power supply outputs that are incompatiblein frequency, voltage levels or some other electrical parameter witheach other). Adapter 200 allows accessory 220 to communicate with host215. In some embodiments connector 202 is similar to connector 100discussed in FIGS. 13A-C and has a pinout as discussed with respect toFIG. 14 that enables the connector to be coupled to a host device inwhich receptacle connector 216 corresponds to connector 140 shown inFIG. 15. Also in some embodiments connector 205 is a 30-pin connector,such as the 30-pin connector employed on Apple iPod and iPhone devices,that has a pinout as shown in FIG. 28B.

As shown in FIG. 28A, adapter 200 includes conversion circuitry 201within housing 204 that converts signals and voltages received fromaccessory 220 over contacts of connector 205 to signals and voltagesthat can be transmitted over connector 202 and processed by host device215. The converters also convert signals and voltages sent by host 215over contacts 206(1) . . . 206(8) to signals and voltages that can betransmitted over connector 205 and processed by accessory 220. In oneembodiment, conversion circuitry 201 includes an audio/video converter207, a data converter 208 and a power converter 209. Other embodimentsinclude only one or two of converters 207, 208 and 209 or include othertypes of converters altogether.

Audio/video converter 207 can be a one-way converter (e.g., onlyconverts video and/or audio data sent from the host to a format that canbe received and processed by the accessory or only converts video and/oraudio data sent from the accessory to a format that can be received andprocessed by the host) or a two-way converter (i.e., converts videoand/or audio data sent between the host and the accessory in bothdirections). In one particular embodiment, audio/video converter 207 isa one-way converter that converts digital audio and digital video datasent over USB data lines of connector 202 into analog audio and analogvideo signals. In another embodiment converter 207 only converts audiodata and adapter 200 does not support the conversion of video databetween host 215 and accessory 220.

Similarly, data converter 208 can be a one-way or two-way dataconverter. In one embodiment, data converter 208 is capable oftranslating data signals received over a first communication protocolused by accessory 220 and connector 205 to either a USB protocol or UARTprotocol used by connector 202 and host 215. In another embodiment,connectors 202 and 205 each support USB and UART communication protocolsand data converter 208 passes USB signals between the two connectorswithout conversion but converts the UART signals received from each ofhost 215 and accessory 220 to a format appropriate for the other of host215 and accessory 220. Data converter 208 can also process control andID signals received over connector 205 as may be required to communicatewith the accessory. Power converter 209 can convert a first DC voltagereceived from accessory 220 over connector 205 to a second DC voltagethat can be transmitted to host 215 over connector 202, and can converta third DC voltage received from the host 215 over connector 202 to afourth DC voltage provided to the accessory 220 through connector 205.

The pinout of connector 202 includes one set of USB 2.0 differentialdata contacts and one set of UART transmit/receive contacts as shown inFIG. 23. The ID contact is coupled to an ID module 208 a that includes amemory that stores information to inform the host that two of the datacontacts are dedicated for USB 2.0 communication while the other twodata contacts are dedicated to UART signals. A current regulator 208 bis operatively coupled to the two centrally located power contacts206(4), 206(5) to regulate current to the host when connector 206 isconnected to an accessory or other device that enables charging.

In some embodiments adapter 202 can include two levels ofauthentication. In a first level, adapter 202 authenticates itself tohost 215 through its connection to the host via connector 202 andconnector 216. As described above with respect to other accessories, inone embodiment this level of authentication can be performed anauthentication module 208 c over one of the sets of data contacts(either the USB or UART contacts) after the contacts in the host'sreceptacle connector are configured, and in another embodiment it can bedone by an authentication module connected to the ID contact as aninitial part of the handshaking algorithm between the host and adapter200. After the adapter is authenticated and in communication with thehost over contacts 202, a second level of authentication can occur wherean authentication processor 210 in adapter 200 authenticates accessory220 connected to it via connector 205 and connector 222 according to anauthentication protocol that accessory 220 would normally employ whenconnecting to a host that the accessory 220 was designed to operatewith.

In particular embodiments where connector 205 has a pinout as shown inFIG. 28B and adapter converts digital video data received over connector202 to analog video data out sent over connector 205, the circuitry ofadapter 200 can be connected to contacts within connectors 202 and 205as shown in Table 1 (for an adapter in which connector 202 has a pinoutcompatible with pinout 106 a) or as shown in Table 2 (for an adapter inwhich connector 202 has a pinout compatible with pinout 106 b) below.

TABLE 1 Connector 202 Adapter 200 Connector 205 Contacts CircuitryContacts USB: 202(2), 202(3) Audio/Video Contacts 21, 22, 23, Converter207 27, 28 USB: 202(2), 202(3); Data Converter Contacts 4, 6, 10, 18,UART: 202(6), 202(7) 208 19, 20, 24, 30 (used as device detect) Pwr:202(4), 202(5); Power Converter Contacts 8, 13 Acc_Pwr: 202(1) 209 GND:Ground ring Ground Contacts 1, 2, 15, 16, via side contacts and 29 N/ANo Connection Contacts 3, 5, 7, 9, 11, 12, 14, 17, 25, 26

TABLE 2 Connector 202 Adapter 200 Connector 205 Contacts CircuitryContacts USB: 202(2), 202(3) Audio/Video Contacts 21, 22, 23, 27, 28Converter 207 USB: 202(2), 202(3); Data Converter Contacts 4, 6, 10, 18,19, 20, UART: 202(6), 202(7) 208 24, 30 (used as device detect) Pwr:202(5); Power Converter Contacts 8, 13 Acc_Pwr: 202(4) 209 GND: 202(8)and Ground Contacts 1, 2, 15, 16, and 29 side contacts N/A No ConnectionContacts 3, 5, 7, 9, 11, 12, 14, 17, 25, 26In another embodiment where adapter 200 does not support the conversionof video data, the contact-to-adapter circuitry connections set forth inTable 1 can be used expect that contacts 21, 22, and 23 are left in anopen state and not connected to active circuitry within the adapter.Adapter 200 can also include a microcontroller (not shown) that cancommunicate with accessory 220 using a protocol that the accessory wouldnormally use to communicate with a host device that the accessory iscompatible with. For example, in one embodiment adapter 200 includes amicrocontroller that supports communication with accessory 220 using theiAP protocol employed by an Apple iPod or iPhone device. Some or all ofthe conversion circuitry 200 can be part of the microcontroller or itcan be separate circuitry. The microcontroller can also set selectedcontacts of connector 205 (e.g., contacts 13, 18-20 and 30, which isused as iPod detect) to an open state so that the accessory does notrecognize that it is connected to a host until after adapter 200authenticates itself to the host and the host configures its contacts toallow communication between the host and adapter 200. Once the host andadapter are operatively connected and in full communication with eachother, adapter 200 can connect the previously open/floating contactswith appropriate circuitry so that the accessory recognizes it has beenconnected to the adapter and can respond to any authentication requestsfrom adapter 200 to initiate and complete a communication link betweenthe adapter and accessory and then ultimately the host to the accessoryvia adapter 200.

Reference is now made to FIGS. 29, 30A-30T and 31, regarding the stepsassociated with the manufacture and assembly of connector 300 (see FIG.30T). FIG. 29 is a flow chart that illustrates the general stepsassociated with the manufacture and assembly of connector 300 accordingto one embodiment of the invention. FIGS. 30A-30T depict connector 300at the various stages of manufacture set forth in FIG. 29. FIG. 31 is aflow chart that further details the general step of attaching thecontact assembly to the PCB, identified as step 130 in the generalmanufacturing and assembly process illustrated in FIG. 29.

Now referring to FIGS. 30A-30D, the manufacture of connector 300 may beinitiated with the fabrication of ground ring 305, the construction ofprinted circuit board (PCB) 304, and the construction of contactassemblies 316 a, 316 b (FIG. 29, steps 122, 124 and 126) each of whichcan occur independent of the others in any order. In step 122, groundring 305 (see FIG. 30A) may be fabricated using a variety of techniquessuch as, for example, a metal injection molding process (MIM), a coldheading process or a billet machining process. A MIM process may providea great deal of flexibility in achieving a desired geometry and canresult in a part that is close to the final desired shape with minimalpost machining operations. In some embodiments, alternative processessuch as plastic injection molding and plating may be used to form groundring 305. Pockets 302 a, 302 b and window 307 may be machined or moldedinto the ground ring and the surface of the ground ring can be smoothedusing a media blasting process. Further, it may be desirable to grind ormachine surfaces of the ground ring such as flats 319 a, 319 b on thetop and bottom of the ground ring. Grinding and machining operations canbe used to create tightly toleranced features. For example, flats 319 a,319 b may be precision ground to form a pair of surfaces that aresubstantially flat and a precise distance apart. Tightly tolerancedcomponent geometry may be beneficial for subsequent assembly operationsand may further benefit the performance of particularly smallconnectors. In one embodiment, the perimeter of the connector body isless than 30 mm. Ground ring 305 may be plated with one or more metalsto achieve the desired finish.

PCB 304 (see FIGS. 30B-30C), which is fabricated in step 124, may be atraditional epoxy and glass combination or may be any equivalentstructure capable of routing electrical signals. For example, someembodiments may use a flexible structure comprised of alternating layersof polyimide and conductive traces while other embodiments may use aceramic material with conductive traces or a plastic material processedwith laser direct structuring to create conductive traces. The PCB maybe formed with a set of conductor bonding pads 310 disposed at one endand a set of contact bonding pads 312(1) . . . 312(8) disposed at theopposing end. In one embodiment the contact bonding pads are each splitalong a transverse direction into two separate bonding pads. The PCB mayalso be equipped with one or more ground spring bonding pads 301 toelectrically connect one or more ground springs 320, as illustrated inFIG. 30D. Additionally, a set of component bonding pads 314 may beformed on the PCB to electrically connect one or more active or passiveelectronic components such as, for example, integrated circuits (ICs),resistors or capacitors. The embodiments depicted herein are forexemplary purposes only, other embodiments may have a differentarrangement of bonding pads 301, 314, 310, 312(1) . . . 312(8), more orless bonding pads, as well as bonding pads formed on either or both ofthe opposing sides of PCB 304, and fewer, more or different electroniccomponents.

Exemplary electronic components 308 a, 308 b are depicted on either sideof PCB 304 (see FIG. 30C). In some embodiments a conductive epoxy isused to electrically attach the electronic components to PCB 304. Inother embodiments a solder alloy may be employed using myriadtechnologies such as, for example, through-hole mounting, stencil printand reflow, chip-on-board, flip-chip or other appropriate connectionmethod. In one embodiment a stencil printing process is used to disposesolder paste on component bond pads 314. Electronic components 308 a.308 b are then disposed on the solder paste and a convective heatingprocess can be used to reflow the solder paste, attaching the electroniccomponents to the PCB. The solder alloy may be a lead-tin alloy, atin-silver-copper alloy, or other suitable metal or metallic alloy.

The same solder reflow attachment process may be used to attach a groundspring 320 to PCB 304. The ground spring is depicted in more detail inFIG. 30D. Ground spring 320 may be comprised of a phosphor-bronze alloyor other metal and optionally plated with nickel and gold. The groundspring may further have one or more spring arms 322 a, 322 b and one ormore protuberances 324 a, 324 b with one or more perforations therebetween. The perforations between the protuberances may improve themechanical strength of the attachment of ground spring 320 to PCB 304which help center PCB 304 within ground ring 305 during the assemblyprocess as described below and provide an additional ground contactbetween PCB 304 and the ground ring.

During the electronic component attachment process, solder paste may bedeposited on contact bonding pads 312(1) . . . 312(8), and reflowed.FIG. 30C depicts solder bumps 313(1) . . . 313(8) that are formed on thecontact pads during reflow processing. The solder paste forms a bumpduring reflow processing due to the high surface tension of the solderwhen in its liquid state.

In some embodiments, after the components are attached to PCB 304, theassembly may be washed and dried. However, in other embodiments theassembly may not be washed until subsequent processing. In otherembodiments a no-clean flux is used to aid the soldering process andthere is no wash process. In further embodiments a no-clean or acleanable flux is used to aid the soldering process and the assembly iswashed. Finally, some or all of electronic components 308 a, 308 b maybe encapsulated with a protective material such as, for example, anepoxy, a urethane or a silicone based material. In some embodiments theprotective encapsulant may provide mechanical strength for improvedreliability and/or environmental protection from moisture for sensitiveelectronic components. In further embodiments the protective encapsulantmay improve the dielectric breakdown voltage performance of connector300. The encapsulant may be applied with an automated machine or with amanual dispenser.

The next step of assembly may involve inserting PCB 304 through a backopening of ground ring 305 so that solder bumps 313(1) . . . 313(8) arepositioned within window 307 (FIG. 29, step 128; FIGS. 30E and 30F).FIG. 30E depicts PCB 304 inserted into ground ring 305. FIG. 30F depictsa longitudinal cross-section view of the assembly shown in FIG. 30Etaken through line A-A′ and contact pads 313(2). FIG. 30F depicts groundspring arms 322 a, 322 b in contact with the top and bottom surfaces ofground ring 305. Also, it can be seen that ground ring protuberances 324a, 324 b define the maximum off-center position PCB 304 can occupywithin the ground ring. More specifically, PCB 304 can only movevertically within ground ring 304 as far as the protuberances allow.Further, it can be seen that solder bumps 313(1) . . . 313(8) disposedon contact bonding pads 312(1) . . . 312(8) are aligned within window307. In some embodiments the next step of assembly comprises depositingflux on solder bumps 313(1) . . . 313(8) through window 307. This can bedone, for example, with an automated atomized spray nozzle, or by anoperator with a dispenser.

Next, contact assemblies 316 a, 316 b (formed in FIG. 29, step 126) maybe positioned within window 307 on each side of ground ring 305 forattachment to PCB 304 (FIG. 29, step 130, FIG. 30G). The contactassemblies employed in some embodiments are illustrated in FIGS.30H-30J. FIG. 30H shows a top perspective view while FIG. 30I shows aplan view from the bottom and FIG. 30J shows a side view. Each contactassembly 316 a, 316 b may include a molded frame 315 that can be formedfrom a dielectric material such as polypropylene. In other embodimentsthe frame is made of a liquid crystal polymer that may be partiallyfilled with glass fiber. One embodiment has eight contacts 306(1) . . .306(8) that are insert molded and secured by frame 315. Frame 315 may beequipped with one or more alignment posts 323 that protrude from abottom surface of frame 315 as shown in FIG. 30F. Alignment posts 323may be tapered and may have a beveled distal end fit within alignmentrules in PCB 304 and are designed to align frame 315 with PCB 304. Insome embodiments, the frame may have alignment tabs 318 disposed on theperimeter of the frame that align each frame 315 within openings 307.Further, the frame may have one or more crushable combs 325(1) . . .325(8) that protrude from the bottom surface of the contact assembly 316a, 316 b and help ensure correct spacing between frame 315 and PCB 304in the vertical direction.

Each contact 306(1) . . . 306(8) in contact assembly 316 a, 316 b can bemade from a variety of conductive materials, for example,phosphor-bronze, copper or stainless steel. Further, the contacts can beplated to improve their performance and appearance with, for example,nickel/gold, multi-layer nickel/gold, nickel/palladium, or any otheracceptable metal. The contacts may be cut to size in a progressivestamping and forming process from a metal sheet and insert molded inframe 315. Each contact may be comprised of more than one metalliccomponent and further, each contact may have one or more metallicprotrusions 321(1) . . . 321(16) disposed on the bottom surface of thecontact assembly. FIG. 30I depicts the bottom view of one embodimentwith eight contacts, where each contact has two protrusions. FIG. 30Jshows a side view of an exemplary contact assembly 316 a, 316 b where itcan be seen that crushable combs 325(1) . . . 325(8) protrude a greaterdistance from the bottom of the contact assembly than do contactprotrusions 321(1) . . . 321(16).

Reference is now made to FIGS. 30K and 30L to illustrate the contactassembly attachment process for one particular embodiment. The detailedsteps in the flow chart depicted in FIG. 31 will be used to illustratethe process employed in this embodiment. Ground ring 305 and PCB 304 maybe placed in a fixture to hold the components in place (FIG. 31, step130 a; FIG. 30K). Contact assembly 316 a can be positioned in window 307of ground ring 305 and alignment posts 323 may be engaged with guideholes 326 in PCB 304 (FIG. 31, step 130 b). The contact assemblyalignment tabs 318 may precisely position contact assembly 316 a inwindow 307. Crushable combs 325(1) . . . 325(8) may be in physicalcontact with PCB 304.

Now referring to FIG. 30K, a hot bar tool 328 with a step 329 can beused to hot bar solder contact assembly 316 a to PCB 304. In step 130 c,the hot bar tool may be heated to a temperature above the meltingtemperature of solder bumps 313(1) . . . 313(8). For example, if thesolder bumps are composed of a tin/silver/copper alloy comprised ofapproximately three percent silver, one-half percent copper with theremainder tin, the hot bar tool may be heated above 221 degreescentigrade. The higher the temperature of the hot bar tool, the fasterthe solder may reflow. In step 130 d, the hot bar tool may travel down,in the direction of arrow 331, towards the contact assembly until itphysically touches the top surface of contacts 306(1) . . . 306(8). Instep 130 e, the hot bar tool may push the contact assembly further inthe direction of arrow 331, partially deforming crushable combs 325(1) .. . 325(8) against PCB 304. The crushable combs may be designedspecifically for this purpose and may impart a controlled amount offorce resisting movement of contact assembly 316 a in the direction ofarrow 331. Alignment tabs 318 and alignment posts 323 may keep thecontact assembly centered in window 307 (see FIG. 30A) during theassembly process. Step 329 of hot bar tool 328 may be precision formedto maintain the top surface of contacts 306(1) . . . 306(8) coplanar andat a controlled height during the attachment process. In step 130 e, thecontact assembly may be further pushed in the direction of the arrowuntil contact protrusions 321(1) . . . 321(16) come into contact withsolder bumps 313(1) . . . 313(8). Hot bar tool 328 may be configured toimpart a controlled force in the direction of arrow 331 at this time sono damage to the contact assembly results.

As mentioned above, solder bumps 313(1) . . . 313(8) may be coated withflux. In some embodiments the coating of flux may not only improve thewetting of the solder to contact protrusions 321(1) . . . 321(16), itmay also enable more efficient heat transfer from contacts 306(1) . . .306(8) to the solder bumps. In step 130 f, hot bar tool 328 may transferthermal energy through the contacts and into the solder bumps. Once anadequate amount of thermal energy has been transferred into the solderbumps, they may transition to a liquid state when heated above theirmelting temperature. Once in a liquid state, the solder bumps offerlittle resistance to additional movement of contact assembly 316 a inthe direction of arrow 331. In step 130 g, the contact assembly may thenbe pushed further by the hot bar tool, causing increased deformation ofcrushable combs 325(1) . . . 325(8), until the hot bar tool “stops” onflat 319 a of ground ring 305. FIG. 30L depicts the stop position of thehot bar tool. In this figure it can be seen that step 329 of hot bartool 328 may be used to precisely position the top surface of contacts306(1) . . . 306(8) a known distance below flat 319 a of ground ring305. In some embodiments, step 329 has a height between 0.1 and 0.01 mmand thus recesses the contacts 306(1) . . . 306(8) that same amount fromsurface 319 a of ground ring 305. In other embodiments, step 329 is notincluded and the contacts are pressed flush with surface 319 a. Also,during step 130 g, contact protrusions 321(1) . . . 321(16) on thebottom surface of contact assembly 316 a may be wetted by the liquefiedsolder bumps 313(1) . . . 313(8). In step 130 h, the hot bar tool maythen be cooled until the liquefied solder bumps cool to a temperaturebelow the liquidus temperature of the solder alloy and solidify. In step130 i, the hot bar tool may then be then retracted and the assembly canbe removed from the fixturing.

In some embodiments the contact attachment process is performed on oneside of ground 305 ring at a time, while in other embodiments theprocess is performed simultaneously on both sides of the ground ring. Insome embodiments crushable combs 325(1) . . . 325(8) may deform between0.02 mm and 0.12 mm. In other embodiments the crushable combs may deformbetween 0.05 mm and 0.09 mm. In some embodiments the heating of thecrushable combs by hot bar tool 328 makes them easier to deform. Thepartially assembled connector may look like FIG. 30M with contactassemblies 316 a, 316 b installed in either side of ground ring 305. Thepartially assembled connector may then be cleaned.

The next step of assembly may involve placing a partially assembledconnector (see FIG. 30M) in an insert molding tool and forming athermoplastic or similar dielectric overmold 338 around contacts 306(1). . . 306(8) and within window 307 of ground ring 305 (FIG. 29, step132; FIGS. 30M-30P). This process may provide a smooth and substantiallyflat mating surface 341 in the contact region of ground ring 305. FIG.30N illustrates the insert molding process of one embodiment. An insertmolding tool 335 may be configured to seal against the top surfacesground ring 305. A step 336 on mold tool 335 may simultaneously sealagainst the top surfaces of contacts 306(1) . . . 306(8). The mold toolmay further be equipped to seal against PCB 304. To simultaneously sealall of these surfaces and protect against dielectric overmold bleeding,the insert mold tool may be equipped with spring loaded inserts toaccommodate dimensional variations of connector components. The insertmold tool may also be configured to inject dielectric overmold 338 fromthe rear of the connector, shown generally by arrow 337. In oneembodiment the insert mold tool has a recessed gate for injecting thedielectric overmold. In some embodiments, ground spring protuberances324 a, 324 b (see FIG. 30F) may accurately maintain the position of PCB304 within ground ring 305 during the dielectric overmold injectionprocess. In some embodiments, dielectric overmold 338 may bepolyoxymethylene (POM). In other embodiments, dielectric overmold 338may be a nylon-based polymer.

FIG. 30O depicts one embodiment after the insert molding process. Insome embodiments, a mating surface 341 may be disposed below the topsurface of ground ring 305 and be substantially coplanar with the topsurface of contacts 306(1) . . . 306(8). FIG. 30P shows a simplifiedcross-section of FIG. 30O in the region of mating surface 341. From thisillustration it can be seen that mating surface 341 may reside in adepression below the top surface of the ground ring. In some embodimentsthe depression may be between 0.01 to 0.1 mm below the top surface ofground ring 305. This depression may protect the contacts from touchingsurfaces, such as that of a mating device, potentially causing damage tothe top surface of the contacts. In some embodiments the recess mayextend around the entire perimeter of window 307 (see FIG. 30M). Infurther embodiments the recess may be deeper in some areas and shallowerin others. In other embodiments the recess may be deeper towards therear of the connector and substantially coplanar with the top surface ofground ring 305 towards the distal end of the connector. In yet furtherembodiments, mating surface 341 of dielectric overmold 338 may besubstantially coplanar with flat 319 a of ground ring 305. In someembodiments, dielectric overmold 338 may be used to aid in retaining thecontacts within the connector.

When connector 300 is part of a cable, the next step of assembly maycomprise attaching a cable bundle 342 to the partially assembledconnector (FIG. 29, step 134; FIG. 30Q). The cable bundle may haveindividual conductors (e.g., wires) 343, for attachment to conductorbonding pads 310 of PCB 304. The individual conductors may be cut andstripped and the jacket of the cable bundle may also be cut andstripped. Each conductor may be soldered to its respective conductorbonding pad using an automated, a semi-automated or a manual process. Inone embodiment the conductors are aligned in a fixture and eachconductor is automatically soldered to each conductor bonding pad. Inanother embodiment each conductor is welded to its respective conductorbonding pad. In some embodiments, where connector 300 is part of anelectronic device or accessory that does not attach a cable to theconnector, for example, a docking station, individual wires, a flexcircuit or the like may electrically connect bonding pads 304 tocircuitry in the device. Myriad conductor attachment processes may beused without departing from the invention.

The next several figures illustrate further example assembly steps whenconnector 300 is part of a cable as shown in FIG. 30Q. In suchinstances, the next step of assembly may involve overmolding a portionof the connector, including electronic components attached to PCB 304,and the cable (FIG. 29, step 136; FIG. 30R). A first insert moldingoperation may be performed, encapsulating PCB 304 in plastic material,and forming a connector body 347. A second insert molding process may beperformed afterwards creating a strain relief sleeve 348 attached to therear face of connector body 347 and extending over cable 342 for a shortdistance. In some embodiments the connector body may be made partiallyfrom insert molded plastic and partially from other materials. The firstand second insert molding materials may be any type of plastic or othernon-conductive material. In one embodiment, both materials arethermoplastic elastomers wherein the second insert molding material isof a lower durometer than the first insert molding material. FIG. 30Rdepicts an embodiment with a two piece conductive metal shield 345 a,345 b that may be installed over a portion of connector body 347 andelectrically bonded to ground ring 305 with tab 346. In someembodiments, shield 345 a, 345 b may be installed first and connectorbody 347 may be molded in a subsequent operation. In some embodiments,shield can 346 may be welded to ground ring 305. In some embodimentsshield 345 a, 345 b may be made from steel while in other embodimentscopper or tin alloys may be used.

The next step of assembly may involve attaching an enclosure 349 to body347 (FIG. 29, step 138; FIGS. 30R-30T). In FIG. 30R, enclosure 349 isillustrated in a preassembled position, located on cable bundle 342. Theenclosure may be sized appropriately to slide over connector body 347,substantially enclosing the connector body within the enclosure. Theenclosure can be manufactured from any type of plastic or othernon-conductive material and in one embodiment is made from ABS.

A cross-sectional view of the enclosure 349 is shown in FIG. 30S. Thisfigure further depicts bonding material 350 deposited on two locationson an inside surface of enclosure 349. The bonding material may bedeposited with a syringe and needle assembly 351 as shown, or it can bedeposited with myriad other techniques without departing from theinvention. The final assembly step is shown in FIG. 30T and comprisessliding enclosure 349 over connector body 347 until the enclosuresubstantially encloses the connector body.

Bonding material 350 may be cured, adhering the inside surface ofenclosure 349 to the outside surface of connector body 347. In someembodiments the bonding material may be a cyanoacrylate that cures inthe presence of moisture. In other embodiments the bonding material maybe an epoxy or urethane that is heat cured. Other bonding materials arewell known in the art and may be employed without departing from theinvention.

Embodiments of the invention are suitable for a multiplicity ofelectronic devices, including any device that receives or transmitsaudio, video or data signals among others. In some instances,embodiments of the invention are particularly well suited for portableelectronic media devices because of their potentially small form factor.As used herein, an electronic media device includes any device with atleast one electronic component that may be used to presenthuman-perceivable media. Such devices may include, for example, portablemusic players (e.g., MP3 devices and Apple's iPod devices), portablevideo players (e.g., portable DVD players), cellular telephones (e.g.,smart telephones such as Apple's iPhone devices), video cameras, digitalstill cameras, projection systems (e.g., holographic projectionsystems), gaming systems, PDAs, desktop computers, as well as tablet(e.g., Apple's iPad devices), laptop or other mobile computers. Some ofthese devices may be configured to provide audio, video or other data orsensory output.

FIG. 32 is a simplified illustrative block diagram representing anelectronic media device 400 that includes an audio plug receptacle 405according to embodiments of the present. Electronic media device 400 mayalso include, among other components, connector receptacle 410, one ormore user input components 420, one or more output components 425,control circuitry 430, graphics circuitry 435, a bus 440, a memory 445,a storage device 450, communications circuitry 455 and POM (position,orientation or movement sensor) sensors 460. Control circuitry 430 maycommunicate with the other components of electronic media device 400(e.g., via bus 440) to control the operation of electronic media device400. In some embodiments, control circuitry 430 may execute instructionsstored in a memory 445. Control circuitry 430 may also be operative tocontrol the performance of electronic media device 400. Controlcircuitry 430 may include, for example, a processor, a microcontrollerand a bus (e.g., for sending instructions to the other components ofelectronic media device 400). In some embodiments, control circuitry 430may also drive the display and process inputs received from inputcomponent 420.

Memory 445 may include one or more different types of memory that may beused to perform device functions. For example, memory 445 may includecache, flash memory, ROM, RAM and hybrid types of memory. Memory 445 mayalso store firmware for the device and its applications (e.g., operatingsystem, user interface functions and processor functions). Storagedevice 450 may include one or more suitable storage mediums ormechanisms, such as a magnetic hard drive, flash drive, tape drive,optical drive, permanent memory (such as ROM), semi-permanent memory(such as RAM) or cache. Storage device 450 may be used for storing media(e.g., audio and video files), text, pictures, graphics, advertising orany suitable user-specific or global information that may be used byelectronic media device 400. Storage device 450 may also store programsor applications that may run on control circuitry 430, may maintainfiles formatted to be read and edited by one or more of the applicationsand may store any additional files that may aid the operation of one ormore applications (e.g., files with metadata). It should be understoodthat any of the information stored on storage device 450 may instead bestored in memory 445.

Electronic media device 400 may also include input component 420 andoutput component 425 for providing a user with the ability to interactwith electronic media device 400. For example, input component 420 andoutput component 425 may provide an interface for a user to interactwith an application running on control circuitry 430. Input component420 may take a variety of forms, such as a keyboard/keypad, trackpad,mouse, click wheel, button, stylus or touch screen. Input component 420may also include one or more devices for user authentication (e.g.,smart card reader, fingerprint reader or iris scanner) as well as anaudio input device (e.g., a microphone) or a video input device (e.g., acamera or a web cam) for recording video or still frames. Outputcomponent 425 may include any suitable display, such as a liquid crystaldisplay (LCD) or a touch screen display, a projection device, a speakeror any other suitable system for presenting information or media to auser. Output component 425 may be controlled by graphics circuitry 435.Graphics circuitry 435 may include a video card, such as a video cardwith 2D, 3D or vector graphics capabilities. In some embodiments, outputcomponent 425 may also include an audio component that is remotelycoupled to electronic media device 400. For example, output component425 may include a headset, headphones or ear buds that may be coupled toelectronic media device 400 with a wire or wirelessly (e.g., Bluetoothheadphones or a Bluetooth headset).

Electronic media device 400 may have one or more applications (e.g.,software applications) stored on storage device 450 or in memory 445.Control circuitry 430 may be configured to execute instructions of theapplications from memory 445. For example, control circuitry 430 may beconfigured to execute a media player application that causes full-motionvideo or audio to be presented or displayed on output component 425.Other applications resident on electronic media device 400 may include,for example, a telephony application, a GPS navigator application, a webbrowser application and a calendar or organizer application. Electronicmedia device 400 may also execute any suitable operating system, such asa Mac OS, Apple iOS, Linux or Windows and can include a set ofapplications stored on storage device 450 or memory 445 that iscompatible with the particular operating system.

In some embodiments, electronic media device 400 may also includecommunications circuitry 455 to connect to one or more communicationsnetworks. Communications circuitry 455 may be any suitablecommunications circuitry operative to connect to a communicationsnetwork and to transmit communications (e.g., voice or data) fromelectronic media device 400 to other devices within the communicationsnetwork. Communications circuitry 455 may be operative to interface withthe communications network using any suitable communications protocolsuch as, for example, Wi-Fi (e.g., a 802.11 protocol), Bluetooth, highfrequency systems (e.g., 900 MHz, 2.4 GHz and 5.6 GHz communicationsystems), infrared, GSM, GSM plus EDGE, CDMA, quadband and othercellular protocols, VOIP or any other suitable protocol.

In some embodiments, communications circuitry 455 may be operative tocreate a communications network using any suitable communicationsprotocol. Communications circuitry 455 may create a short-rangecommunications network using a short-range communications protocol toconnect to other devices. For example, communications circuitry 455 maybe operative to create a local communications network using theBluetooth protocol to couple with a Bluetooth headset (or any otherBluetooth device). Communications circuitry 455 may also include a wiredor wireless network interface card (NIC) configured to connect to theInternet or any other public or private network. For example, electronicmedia device 400 may be configured to connect to the Internet via awireless network, such as a packet radio network, an RF network, acellular network or any other suitable type of network. Communicationcircuitry 445 may be used to initiate and conduct communications withother communications devices or media devices within a communicationsnetwork.

Electronic media device 400 may also include any other componentsuitable for performing a communications operation. For example,electronic media device 400 may include a power supply, an antenna,ports or interfaces for coupling to a host device, a secondary inputmechanism (e.g., an ON/OFF switch) or any other suitable component.

Electronic media device 400 may also include POM sensors 460. POMsensors 460 may be used to determine the approximate geographical orphysical location of electronic media device 400. As described in moredetail below, the location of electronic media device 400 may be derivedfrom any suitable trilateration or triangulation technique, in whichcase POM sensors 460 may include an RF triangulation detector or sensoror any other location circuitry configured to determine the location ofelectronic media device 400.

POM sensors 460 may also include one or more sensors or circuitry fordetecting the position orientation or movement of electronic mediadevice 400. Such sensors and circuitry may include, for example,single-axis or multi-axis accelerometers, angular rate or inertialsensors (e.g., optical gyroscopes, vibrating gyroscopes, gas rategyroscopes or ring gyroscopes), magnetometers (e.g., scalar or vectormagnetometers), ambient light sensors, proximity sensors, motion sensor(e.g., a passive infrared (PIR) sensor, active ultrasonic sensor oractive microwave sensor) and linear velocity sensors. For example,control circuitry 430 may be configured to read data from one or more ofPOM sensors 460 in order to determine the location orientation orvelocity of electronic media device 400. One or more of POM sensors 460may be positioned near output component 425 (e.g., above, below or oneither side of the display screen of electronic media device 400).

FIG. 33 depicts an illustrative rendering of one particular electronicmedia device 480. Device 480 includes a multipurpose button 482 as aninput component, a touch screen display 484 as a both an input andoutput component, and a speaker 485 as an output component, all of whichare housed within a device housing 490. Device 480 also includes aprimary receptacle connector 486 and an audio plug receptacle 488 withindevice housing 490. Each of the receptacle connectors 486 and 488 can bepositioned within housing 490 such that the cavity of the receptacleconnectors into which a corresponding plug connector is inserted islocated at an exterior surface of the device housing. In someembodiments, the cavity opens to an exterior side surface of device 480.For simplicity, various internal components, such as the controlcircuitry, graphics circuitry, bus, memory, storage device and othercomponents are not shown in FIG. 33. Embodiments of the inventiondisclosed herein are particularly suitable for use with plug connectorsthat are configured to mate with primary receptacle connector 486, butin some embodiments can also be used with audio plug receptacle 488.Additionally, in some embodiments, electronic media device 480 has onlya single receptacle connector 486 that is used to physically interfaceand connect the device (as opposed to a wireless connection which canalso be used) to the other electronic devices.

As will be understood by those skilled in the art, the present inventionmay be embodied in many other specific forms without departing from theessential characteristics thereof. For example, various embodiments ofthe invention were described above with respect to dual orientationconnectors. Other embodiments include connectors that have more than twopossible insertion orientations. For example, a connector systemaccording to the invention could include a plug connector that has atriangular cross-section to fit within a triangular cavity of acorresponding receptacle connector in any one of three possibleorientations; a plug connector that has a square cross-section and fitswithin a receptacle connector in any one of four possible insertionorientations; a plug connector that has a hexagonal cross-section to fitwithin a corresponding receptacle connector in any one of six possibleorientations; etc. Also, in some embodiments, a plug connector of theinvention is shaped to be inserted into a receptacle connector inmultiple orientations but only includes contacts on a single side of theplug connector. Such a connector can be operatively coupled in anyone ofits multiple orientations to a receptacle connector that has contacts oneach of the surfaces of the interior cavity. As an example, oneembodiment of a plug connector similar to connector 80 shown in FIGS.8A-8B could have contacts formed only in region 46 a and not in region46 b. Such a plug connector could be operatively coupled to a receptacleconnector, such as receptacle connector 85 shown in FIGS. 9A-9B, ineither of two orientations if the receptacle connector had appropriatecontacts on both the upper and lower surfaces of interior cavity 87. Theconnector could also be operatively coupled to receptacle connector 85having contacts only on the upper surface of cavity 87 if it is insertedwithin cavity 87 with side 44 a in an “up” position as shown in FIG. 9A.

As still another example, FIGS. 13A-13C described an embodiment whereeach contact in contact region 46 a is electrically connected to amatching contact in contact region 46 b on the opposite side of theconnector. In some embodiments, only a subset of contacts in region 46 aare electrically connected to contacts in region 46 b. As an example, inone embodiment that includes eight contacts formed in a single rowwithin each contact region 46 a and 46 b similar to connector 100 shownin FIG. 13A, contacts 106(4) and 106(5) in region 46 a are eachelectrically connected to corresponding contacts 106(4) and 106(5) inregion 46 while contacts 106(1) . . . 106(3) and 106(6) . . . 106(8) areelectrically independent from each other and are electricallyindependent from contacts within region 46 b. Thus, such an embodimentmay have fourteen electrically independent contacts instead of theeight. In still other embodiments, none of the contacts in region 46 aare electrically coupled to contacts in region 46 b. Also, in anotherembodiment of adapter 200 connector 202 can be a 30-pin plug connectorhaving the pinout shown in FIG. 28B while connector 205 is an eightcontact receptacle connector similar to receptacle connector 140 shownin FIG. 15.

Also, while a number of specific embodiments were disclosed withspecific features, a person of skill in the art will recognize instanceswhere the features of one embodiment can be combined with the featuresof another embodiment. For example, some specific embodiments of theinvention set forth above were illustrated with pockets as retentionfeatures. A person of skill in the art will readily appreciate that anyof the other retention features described herein, as well as others notspecifically mentioned, may be used instead of or in addition to thepockets. Also, those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific embodiments of the inventions described herein. Suchequivalents are intended to be encompassed by the following claims.

What is claimed:
 1. A dual orientation plug connector comprising: a 180degree symmetrical connector tab adapted to be inserted into areceptacle connector during a mating event, the connector tab havingwidth, height and length dimensions and comprising a frame that definesa shape of the connector tab, the frame having first and second opposingsides extending in the width and length dimensions, and third and fourthopposing sides extending between the first and second sides in theheight and length dimensions, the first side including a first openingand the second side including a second opening directly opposite thefirst opening; a first contact region formed in the first opening of theframe, the first contact region including a first plurality of externalcontacts and dielectric material between each adjacent contact in thefirst plurality of contacts and between each contact in the firstplurality of contacts and the frame; and a second contact region formedin the second opening of the metal frame, the second contact regionincluding a second plurality of external contacts and dielectricmaterial between each adjacent contact in the first plurality ofcontacts and between each contact in the first plurality of contacts andthe frame, wherein at least one individual contact in the firstplurality of contacts is electrically coupled to an individual contactin the second plurality of contacts.
 2. The plug connector set forth inclaim 1 wherein: each of the first and second pluralities of contactsincludes first and second data contacts and a first power contact; thefirst data contact in the first plurality of contacts is electricallyconnected within the frame to the first data contact in the secondplurality of contacts; the second data contact in the first plurality ofcontacts is electrically connected within the frame to a second datacontact in the second plurality of contacts; and the first power contactin the first plurality of contacts is electrically connected within theframe to a first power contact in the second plurality of contacts. 3.The plug connector set forth in claim 2 wherein each contact in thefirst plurality of contacts is electrically connected within the frameto a contact in the second plurality of contacts.
 4. The plug connectorset forth in claim 1 wherein the number of contacts in the firstplurality of contacts is equal to the number of contacts in the secondplurality of contacts.
 5. The plug connector set forth in claim 4wherein the first plurality of contacts are spaced apart along a singlerow within the first contact region, the second plurality of contactsare spaced apart along a single row within the second contact region,and each contact in the first plurality of contacts is positioneddirectly opposite a contact in the second plurality of contacts.
 6. Theplug connector set forth in claim 5 wherein each of the first and secondpluralities of contacts consists of eight contacts located insequentially numbered contact locations.
 7. The plug connector set forthin claim 6 wherein the first plurality of contacts includes a first pairof data contacts at contact locations 2 and 3 and wherein the datacontact at contact location 2 is electrically coupled to a data contactin the second plurality of contacts positioned directly oppositelocation 2 and the data contact at contact location 3 is electricallycoupled to a data contact in the second plurality of contacts positioneddirectly opposite location
 3. 8. The plug connector set forth in claim 7wherein the first plurality of contacts further includes a second pairof data contacts at contact locations 6 and 7 and wherein the datacontact at contact location 6 is electrically coupled to a data contactin the second plurality of contacts positioned directly oppositelocation 6 and the data contact at contact location 7 is electricallycoupled to a data contact in the second plurality of contacts positioneddirectly opposite location
 7. 9. The plug connector set forth in claim 7wherein the first plurality of contacts further includes a first powercontact positioned in one of contact locations 4 or 5 that iselectrically coupled to a second power contact in the second pluralityof contacts positioned directly opposite one of contact locations 4 or5.
 10. The plug connector set forth in claim 1 wherein the frame is ametal frame.
 11. The plug connector set forth in claim 1 furthercomprising first and second retention features formed on the third andfourth sides of the electrically conductive frame, respectively, adaptedto engage with retention features on a corresponding receptacleconnector.
 12. A dual orientation plug connector comprising: a body; a180 degree symmetrical connector tab coupled to and extendinglongitudinally away from the body, the connector tab having width,height and length dimensions and comprising an electrically conductiveframe that defines a shape of the connector tab, the electricallyconductive frame having first and second opposing sides extending in thewidth and length dimensions, and third and fourth opposing sidesextending between the first and second sides in the height and lengthdimensions, and a tip extending in the width and height dimensions at adistal end of the frame between the first and second opposing exteriorsurfaces and between the third and fourth opposing exterior surfaces,wherein the first side of the frame includes a first opening and thesecond side of the frame includes a second opening directly opposite thefirst opening; a first contact region formed in the first opening of theelectrically conductive frame, the first contact region including afirst plurality of external contacts spaced apart along a single row anddielectric material filled in between each adjacent contact in the firstplurality of contacts and between each contact in the first plurality ofcontacts and the electrically conductive frame; a second contact regionformed in the second opening of the electrically conductive frame, thesecond contact region including a second plurality of external contactsspaced apart along a single row and dielectric material filled inbetween each adjacent contact in the first plurality of contacts andbetween each contact in the first plurality of contacts and theelectrically conductive frame, wherein each individual contact in thefirst plurality of contacts is electrically connected to an individualcontact in the second plurality of contacts, and each individual contactin the first plurality of contacts is positioned directly opposite anindividual contact in the second plurality of contacts; and first andsecond retention features formed on the third and fourth sides of theelectrically conductive frame, respectively, the first and secondretention features adapted to engage with retention features of acorresponding receptacle connector.
 13. The plug connector set forth inclaim 12 wherein the electrically conductive frame further includes arear surface within the body, the rear surface having a third opening,and wherein the plug connector further comprises: a substrate extendingfrom the body through the third opening of the electrically conductiveframe, the substrate having a first and second opposing substrate sides,the first substrate side facing the first side of the electricallyconductive frame and the second substrate side facing the second side ofthe electrically conductive frame; a first plurality of contact bondingpads formed on the first substrate side, wherein each of the firstplurality of contact bonding pads is electrically coupled to a contactin the first plurality of contacts; a second plurality of contactbonding pads on the second substrate side, wherein each of the secondplurality of contact bonding pads is electrically coupled to a contactin the second plurality of contacts; and a plurality of conductorbonding pads formed on the substrate within the body of the connector,wherein at least some individual ones of the plurality of conductorbonding pads are electrically connected to some of the first and secondplurality of contact bonding pads by conductive traces carried by thesubstrate.
 14. The plug connector set forth in claim 12 wherein each ofthe first and second pluralities of contacts consists of eight contactslocated in sequentially numbered contact locations.
 15. The plugconnector set forth in claim 14 wherein: the first plurality of contactsincludes a first pair of data contacts at contact locations 2 and 3, asecond pair of data contacts at contact locations 6 and 7, and a firstpower contact positioned in one of contact locations 4 or 5; the datacontact at contact location 2 is electrically coupled to a data contactin the second plurality of contacts positioned directly oppositelocation 2; the data contact at contact location 3 is electricallycoupled to a data contact in the second plurality of contacts positioneddirectly opposite location 3; the data contact at contact location 6 iselectrically coupled to a data contact in the second plurality ofcontacts positioned directly opposite location 6; the data contact atcontact location 7 is electrically coupled to a data contact in thesecond plurality of contacts positioned directly opposite location 7;and the first power contact is electrically coupled to a power contactin the second plurality of contacts positioned directly opposite one ofcontact locations 4 or
 5. 16. The plug connector set forth in claim 15wherein the data contacts at contact locations 2 and 3 make up a firstpair of high speed data contacts, the data contacts at contact locations6 and 7 make up a second pair of high speed data contacts, and eachcontact at contact locations 1, 4, 5 and 8 in the first and secondpluralities of contacts is designated to carry DC signals or signalsthat operate at a rate that is at least two orders of magnitude slowerthan that of the high speed data contacts.
 17. The plug connector setforth in claim 12 wherein the electrically conductive material is ametal.
 18. The plug connector set forth in claim 12 wherein the body isa housing associated with an electronic device.
 19. A dual orientationplug connector comprising: a body; a 180 degree symmetrical connectortab coupled to and extending longitudinally away from the body, theconnector tab having width, height and length dimensions and comprisinga metal frame that defines a shape of the connector tab, theelectrically conductive frame having first and second opposing sidesextending in the width and length dimensions, and third and fourthopposing sides extending between the first and second sides in theheight and length dimensions, and a tip extending in the width andheight dimensions at a distal end of the frame between the first andsecond opposing exterior surfaces and between the third and fourthopposing exterior surfaces, wherein the first side of the frame includesa first opening and the second side of the frame includes a secondopening directly opposite the first opening; a first contact regionformed in the first opening of the electrically conductive frame, thefirst contact region comprising a first set of eight external contactsspaced apart along a single row in sequentially numbered contactlocations and dielectric material filled in between each adjacentcontact in the first set of contacts and between each contact in thefirst set of contacts and the electrically conductive frame, the firstset of contacts including a first pair of data contacts at contactlocations 2 and 3, a second pair of data contacts at contact locations 6and 7, and a first power contact positioned between the first and secondpairs of data contacts; a second contact region formed in the secondopening of the electrically conductive frame, the second contact regionincluding a second set of eight external contacts and dielectricmaterial filled in between each adjacent contact in the first set ofcontacts and between each contact in the first set of contacts and theelectrically conductive frame; wherein each contact in the second set ofeight external contacts is positioned directly opposite an individualcontact in the first set of eight external contacts; the data contact atcontact location 2 is electrically coupled to a data contact in thesecond set of contacts positioned directly opposite location 2; the datacontact at contact location 3 is electrically coupled to a data contactin the second set of contacts positioned directly opposite location 3;the data contact at contact location 6 is electrically coupled to a datacontact in the second set of contacts positioned directly oppositelocation 6; the data contact at contact location 7 is electricallycoupled to a data contact in the second set of contacts positioneddirectly opposite location 7; and the first power contact iselectrically coupled to a power contact in the second set of contactspositioned directly opposite one of contact locations 4 or
 5. 20. Theplug connector set forth in claim 19 further comprising: a substrateextending from the body through an opening of a rear surface of themetal frame, the substrate having a first and second opposing substratesides, the first substrate side facing the first side of the metal frameand the second substrate side facing the second side of the metal frame;a first plurality of contact bonding pads formed on the first substrateside, wherein each of the first plurality of contact bonding pads iselectrically coupled to a contact in the first set of contacts; a secondplurality of contact bonding pads on the second substrate side, whereineach of the second plurality of contact bonding pads is electricallycoupled to a contact in the second set of contacts; a plurality ofthrough holes in the substrate, wherein each individual contact in thefirst set of contacts is electrically connected to an individual contactin the second set of contacts via one of the plurality of through holes;a first retention feature formed on the third side of the electricallyconductive frame, the first retention adapted to engage with a retentionfeature on a corresponding receptacle connector and function as a groundcontact for the plug connector; and a second retention feature formed onthe fourth side of the electrically conductive frame, the secondretention adapted to engage with a retention feature on a correspondingreceptacle connector and function as a ground contact for the plugconnector.